Object tracking in packaging systems

ABSTRACT

A packaging system includes a conveyance system, a package forming system, and a tracking system. The conveyance system is configured to receive objects and to convey the objects through the packaging system. Spacing between the objects is non-uniform as the objects are received by the conveyance system. The package forming system is configured to feed a packaging material to form a tube of the packaging material and to seal the tube of the packaging material around the objects to form packages of the packaging material around the objects. The tracking system configured to track locations of the objects as the objects are conveyed through the packaging system on the conveyance system. In some cases, the tracking system is configured to track locations of the objects independently of any marks on the packaging material and/or independently of the location of inducting documents placed on the objects.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of International ApplicationNo. PCT/US2018/047625, filed Aug. 23, 2018, which claims the benefit ofU.S. Provisional Patent Application No. 62/558,902, filed Sep. 15, 2017,the contents of each of which are hereby incorporated by reference intheir entirety. The present application is also a continuation-in-partof U.S. patent application Ser. No. 15/571,533, filed Nov. 3, 2017,which is a national stage entry under 35 U.S.C. § 371 of InternationalApplication No. PCT/US2016/030630, filed May 4, 2016, which claims thebenefit of U.S. Provisional Patent Application No. 62/157,164, filed May5, 2015, the contents of each of which are hereby incorporated byreference in their entirety.

BACKGROUND

The present disclosure is in the technical field of object packaging.More particularly, the present disclosure is directed to tracking objectlocations as the objects are conveyed through a packaging system.

Consumers frequently purchase goods from mail-order or internetretailers, which package and ship the goods to the purchasing consumervia a postal service or other carrier. Millions of such packages areshipped each day. These items are normally packaged in small containers,such as a box or envelope. To protect the items during shipment, theyare typically packaged with some form of protective dunnage that may bewrapped around the item or stuffed into the container to preventmovement of the item and to protect it from shock.

A common type of packaging envelope is known as a “padded mailer.”Padded mailers are generally shipping envelopes that have padded wallsto protect the contents of the mailer. Padded mailers generally includea single or double wall envelope, with paper dunnage or air cellularcushioning material to protect the packaged object. While such paddedmailers have been commercially successful, they are not withoutdrawbacks. For instance, because trapped or confined air is generallythe cushioning medium, the space required to store such mailers is notinsignificant. Further, in order not to require an inordinately largeamount of storage space, the padded mailers are typically limited tohaving relatively thin padding. In another example, inflatable mailers(i.e., mailers that have an integral inflatable cushioning material) canbe inflated just prior to packaging and shipment, but inflation of theseinflatable mailers can be a slow, cumbersome, and labor-intensiveprocess. Moreover, padded mailers are typically used to protect objectsduring shipment, but are typically not used at other times, such astimes when objects are stored in inventory.

Some packaging systems, called form-fill-seal machines, form a tube ofpackaging material (e.g., polyethylene foam, inflatable cushioningmaterial, etc.) into which the objects are fed. The packaging systemsthem seal the package material around the objects to form packagesaround the objects. These systems have a number of benefits, such as thespeed with which they are able to form packages around objects. However,existing form-fill-seal machines can be improved to reduce the number offlawed packages created and to increase the appearance of the formedpackages.

SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This summary is not intended to identify key features ofthe claimed subject matter, nor is it intended to be used as an aid indetermining the scope of the claimed subject matter.

In one embodiment, a packaging system includes a conveyance system, apackage forming system, and a tracking system. The conveyance system isconfigured to receive objects and to convey the objects through thepackaging system. Spacing between the objects is non-uniform as theobjects are received by the conveyance system. The package formingsystem is configured to feed a packaging material to form a tube of thepackaging material and further configured to seal the tube of thepackaging material around the objects to form packages of the packagingmaterial around the objects. The tracking system is configured to tracklocations of the objects as the objects are conveyed through thepackaging system on the conveyance system. The tracking system isconfigured to track locations of the objects independently of any markson the packaging material.

In one example, the tracking system includes an infeed scannerconfigured to detect an infeed location of each of the objects as theobjects are fed through an infeed portion of the conveyance system. Inanother example, the infeed scanner is configured to detect the infeedlocation of each of the objects by detecting a leading edge and atrailing edge of each of the objects as the objects are fed through theinfeed portion of the conveyance system. In another example, thetracking system is configured to calculate a longitudinal length of eachof the objects based on the leading edge and the trailing edge of eachof the objects. In another example, the package forming system isconfigured to seal the tube of the packaging material around one of theobjects at locations based on the longitudinal length of the one of theobjects. In another example, the infeed scanner is further configured togenerate a height indication for each of the objects as the objects arefed through the infeed portion of the conveyance system; the heightindication for an object includes at least one of an indication whetherany portion of the object exceeds a predetermined height, an indicationof a height of the leading edge of the object and a height of thetrailing edge of the object, or a height profile of the object from atransverse side of the object; and the package forming system isconfigured to seal the tube of the packaging material around one of theobjects at locations based on a combination of the longitudinal lengthof the one of the objects and the height indication of the one of theobjects.

In another example, the tracking system further includes at least oneconveyor sensor configured to detect movements of the conveyance system.In another example, the tracking system is configured to track locationsof the objects as the objects pass through the packaging system on theconveyance system based on a combination of the infeed location of eachof the objects and the movements of the conveyance system detected bythe at least one conveyor sensor. In another example, the at least oneconveyor sensor includes a plurality of encoders configured detectmovements of each of a plurality of conveyor belts in the conveyancesystem.

In another example, the packaging system further includes a labelingmechanism configured to apply a label on the packaging material, wherethe label is associated with one of the objects, and where the packagingsystem is configured to cause the labeling mechanism to apply the labelto the packaging material based on the tracked location of the one ofthe objects. In another example, the labeling mechanism is configured toapply the label to the packaging material after the packaging materialis formed into the tube and before the tube of the packaging material issealed around the one of the objects. In another example, the packagingmaterials include one or more of a polyethylene-based film, aninflatable cushioning material, or an inflated cushioning material.

In another embodiment, a method includes a conveyance system of apackaging system receiving objects that are non-uniformly spaced as theobjects are received by the conveyance system and conveying the objectsthrough the packaging system. The method further includes a packageforming system of the packaging system feeding a packaging material toform a tube of the packaging material and forming seals in the tube ofthe packaging material around the objects to form packages of thepackaging material around the objects. The method further includes atracking system in the packaging system tracking locations of theobjects independently of any marks on the packaging material as theobjects are conveyed through the packaging system.

In one example, the method further includes an infeed scanner of thetracking system detecting an infeed location of each of the objects asthe objects are fed through an infeed portion of the conveyance system.In another example, detecting the infeed location of each of the objectsincludes detecting a leading edge and a trailing edge of each of theobjects as the objects are fed through the infeed portion of theconveyance system. In another example, the method further includes thetracking system calculating a longitudinal length of each of the objectsbased on the leading edge and the trailing edge of each of the objects.In another example, the package forming system is configured to seal thetube of the packaging material around one of the objects at locationsbased on the longitudinal length of the one of the objects.

In another example, the method further includes the infeed scannergenerating a height indication for each of the objects as the objectsare fed through the infeed portion of the conveyance system; where theheight indication for an object includes at least one of an indicationwhether any portion of the object exceeds a predetermined height, anindication of a height of the leading edge of the object and a height ofthe trailing edge of the object, or a height profile of the object froma transverse side of the object; and where the package forming system isconfigured to seal the tube of the packaging material around one of theobjects at locations based on a combination of a longitudinal length ofthe one of the objects and the height indication of the one of theobjects. In another example, the method further includes at least oneconveyor sensor of the tracking system detecting movements of theconveyance system, where tracking the locations of the objects as theobjects are conveyed through the packaging system on the conveyancesystem is based on a combination of the infeed location of each of theobjects and the movements of the conveyance system detected by the atleast one conveyor sensor. In another example, the at least one conveyorsensor includes a plurality of encoders configured detect movements ofeach of a plurality of conveyor belts in the conveyance system.

In another example, the method further includes a labeling mechanismapplying a label to the packaging material, where the label isassociated with one of the objects, and where the packaging system isconfigured to cause the labeling mechanism to apply the label to thepackaging material based on the tracked location of the one of theobjects. In another example, applying the label to the packagingmaterial occurs after the packaging material is formed into the tube andbefore sealing the tube of the packaging material around the one of theobjects. In another example, the packaging materials include one or moreof a polyethylene-based film, an inflatable cushioning material, or aninflated cushioning material.

In another embodiment, a packaging system includes a conveyance system,a package forming system, and a tracking system. The conveyance systemis configured to receive objects and to convey the objects through thepackaging system, where spacing between the objects is non-uniform asthe objects are received by the conveyance system. The package formingsystem is configured to feed a packaging material to form a tube of thepackaging material and further configured to form transverse seals inthe tube of the packaging material around at least one of the objects toform a package of the packaging material around the at least one of theobjects, where the packaging material includes graphic regionsintermittently spaced in a longitudinal direction of the packagingmaterial. The tracking system is configured to track locations of theobjects as the objects are conveyed through the packaging system on theconveyance system. The conveyance system is configured to position theat least one of the objects in the tube with respect to the packagingmaterial such that the transverse seals do not intersect any of thegraphic regions.

In one example, the packaging system is configured to control operationof the conveyance system based on the tracked location of the at leastone of the objects such that the conveyance system positions the atleast one of the objects with respect to the packaging material suchthat the transverse seals formed in the packaging material do notintersect any of the graphic regions. In another example, the trackingsystem includes an infeed scanner configured to detect an infeedlocation of each of the objects as the objects are fed through an infeedportion of the conveyance system. In another example, the trackingsystem is configured to calculate a longitudinal length of each of theobjects. In another example, the positioning of the at least one of theobjects is based on the longitudinal length of the at least one of theobjects.

In another example, the infeed scanner is further configured to generatea height indication for each of the objects as the objects are fedthrough the infeed portion of the conveyance system. In another example,the positioning of the at least one of the objects is based on theheight indication of the at least one of the objects. In anotherexample, the height indication for the at least one of the objectsincludes at least one of an indication whether any portion of the atleast one of the objects exceeds a predetermined height, an indicationof a height of the leading edge of the object and a height of thetrailing edge of the at least one of the objects, or a height profile ofthe at least one of the objects from a transverse side of the at leastone of the objects.

In another embodiment, a method includes a conveyance system of apackaging system receiving objects that are non-uniformly spaced as theobjects are received by the conveyance system. The method furtherincludes a tracking system of the packaging system tracking locations ofthe objects as the objects pass through the packaging system on theconveyance system. The method further includes a package forming systemof the packaging system forming a tube of packaging material, where thepackaging material includes graphic regions intermittently spaced in alongitudinal direction of the packaging material. The method furtherincludes the conveyance system feeding at least one of the objects intothe tube of the packaging material. The method further includes thepackage forming system forming transverse seals in the tube of thepackaging material to form a package of the packaging material aroundthe at least one of the objects. The feeding of the at least one of theobjects into the tube of the packaging material includes positioning, bythe conveyance system, the at least one of the objects in the tube withrespect to the packaging material such that the transverse seals formedin the packaging material do not intersect any of the graphic regions.

In one example, the method further includes the packaging systemcontrolling operation of the conveyance system based on the trackedlocation of the at least one object such that the conveyance systempositions the at least one of the objects with respect to the film suchthat the transverse seals in the packaging material do not intersect anyof the graphic regions. In another example, the tracking includes thetracking system detecting an infeed location of each of the objects asthe objects are fed through an infeed portion of the conveyance system.In another example, the tracking includes the tracking systemdetermining a longitudinal length of each of the objects. In anotherexample, the positioning of the at least one of the objects is based onthe longitudinal length of the at least one of the objects. In anotherexample, the tracking includes the tracking system determining a heightindication for the at least one of the objects. In another example, thepositioning of the at least one of the objects is based on the heightindication of the at least one of the objects. In another example, theheight indication for the at least one of the objects includes at leastone of an indication whether any portion of the at least one of theobjects exceeds a predetermined height, an indication of a height of theleading edge of the object and a height of the trailing edge of the atleast one of the objects, or a height profile of the at least one of theobjects from a transverse side of the at least one of the objects.

In another embodiment, a packaging system includes a conveyance system,a package forming system, and a tracking system. The conveyance systemis configured to receive objects, where spacing between the objects isnon-uniform as the objects are received by the conveyance system. Thepackage forming system is configured to feed a packaging material toform a tube of the packaging material and to form transverse seals inthe tube of the packaging material. The tracking system is configured totrack locations of the objects as the objects are conveyed through thepackaging system on the conveyance system. The conveyance system isconfigured to feed the objects into the tube of the packaging material.At least one of the objects is located between two of the transverseseals to form a package of the packaging material around the at leastone of the objects. The tracking system is configured to track thelocations of the objects at least by tracking the location of the atleast one of the objects while the at least one of the objects is insideof the tube of the packaging material and inside of the package. Thepackaging system is configured to pass the package to a downstreampackage handling system and to communicate, to the downstream packagehandling system, the location of the at least one object.

In one example, the packaging system is configured to determine that thepackage is flawed and to communicate, to the downstream package handlingsystem, an indication that the package is flawed. In another example,the downstream package handling system is configured to sort the packagefrom other packages that are not flawed based at least on the locationof the package and the indication that the package is flawed receivedfrom the packaging system. In another example, the packaging system isconfigured to determine that the package is flawed is based on at leastone of a determination that the package is lacking one of the objects, adetermination that the package includes an extra one of the objects, afaulty reading of a label on the package, a lack of a label on thepackage, an improper dimension of the package, a transverse seal on thepackage that crosses a graphic region, a user input indicating that thepackage is flawed, or any combination thereof. In another example, thepackaging system is communicatively coupled to the downstream packagehandling system via one or more of a serial connection, a communicationbus, a wired network, or a wireless network.

In another embodiment, a method includes a packaging system receivingobjects that are non-uniformly spaced as the objects are received by aconveyance system, forming a tube of packaging material, and conveyingthe objects through the packaging system, where the conveying includesfeeding the objects into the tube of the packaging material. The methodfurther includes the packaging system forming transverse seals in thetube of the packaging material, where at least one of the objects islocated between two of the transverse seals to form a package of thepackaging material around the at least one of the objects. The methodfurther includes the packaging system tracking locations of the objectsduring the conveying of the objects through the packaging systemindependently of the packaging material, where tracking the locations ofthe objects includes tracking the location of the at least one of theobjects while the at least one of the objects is inside of the tube ofthe packaging material and inside of the package. The method furtherincludes the packaging system passing the package to a downstreampackage handling system, where passing the package includescommunicating, from the packaging system to the downstream packagehandling system the location of the at least one object.

In one example, the method further includes the packaging systemdetermining that the package is flawed, where passing the packagefurther includes communicating, from the packaging system to thedownstream package handling system an indication that the package isflawed. In another example, the downstream package handling system isconfigured to sort the package from other packages that are not flawedbased at least on the location of the package and the indication thatthe package is flawed received from the packaging system. In anotherexample, determining that the package is flawed is based on at least oneof a determination that the package is lacking one of the objects, adetermination that the package includes an extra one of the objects, afaulty reading of a label on the package, a lack of a label on thepackage, an improper dimension of the package, a transverse seal on thepackage that crosses a graphic region, a user input indicating that thepackage is flawed, or any combination thereof. In another example, thepackaging system is communicatively coupled to the downstream packagehandling system via one or more of a serial connection, a communicationbus, a wired network, or a wireless network.

BRIEF DESCRIPTION OF THE DRAWING

The foregoing aspects and many of the attendant advantages of thedisclosed subject matter will become more readily appreciated as thesame become better understood by reference to the following detaileddescription, when taken in conjunction with the accompanying drawings,wherein:

FIG. 1A depicts an embodiment of a packaging system, in accordance withthe embodiments described herein;

FIG. 1B depicts a block diagram of portions of the packaging systemshown in FIG. 1A, in accordance with the embodiments described herein;

FIG. 2A depicts another embodiment of a packaging system, in accordancewith the embodiments described herein;

FIG. 2B depicts a block diagram of portions of the packaging systemshown in FIG. 2A, in accordance with the embodiments described herein;

FIGS. 3A-3D depict instances of a system that determines a heightindication of an object based on whether any portion of the objectexceeds a predetermined height, in accordance with the embodimentsdescribed herein;

FIGS. 4A-4D depict instances of a system that determines a heightindication of an object based on a height of the leading edge of theobject and a height of the trailing edge of the object, in accordancewith the embodiments described herein;

FIGS. 5A-5D depict instances of a system that determines a heightindication of an object based on height profile of the object from atransverse side of the object, in accordance with the embodimentsdescribed herein;

FIG. 6A depicts an example of a packaging system that uses a packagingmaterial having intermittently-spaced graphic regions to form packages,in accordance with the embodiments described herein;

FIGS. 6B and 6C depict, respectively, some of the difficulties with theuse of the packaging material with the intermittently-spaced graphicregions and an embodiment of a package formed so that graphic regionsare not intersected or covered by seals, cuts, or labels, in accordancewith the embodiments described herein;

FIGS. 7A and 7B depict embodiments of systems that include one packagingsystem upstream from a downstream package handling system, in accordancewith the embodiments described herein;

FIGS. 8A and 8B depict two instances of an infeed portion of a packagingsystem that scans inducting documents on objects, in accordance with theembodiments described herein;

FIG. 8C depicts a outfee portion of the packaging system shown in FIGS.8A and 8B where labels are placed on packages based on the location ofthe inducting documents with respect to the objects, in accordance withthe embodiments described herein;

FIGS. 9A and 9B depict two instances of an infeed portion of a packagingsystem that scans inducting documents on objects, in accordance with theembodiments described herein;

FIG. 9C depicts a outfee portion of the packaging system shown in FIGS.9A and 9B where labels are placed on packages based on the location ofthe inducting documents with respect to the objects, in accordance withthe embodiments described herein;

FIG. 10 depicts an example embodiment of a system that may be used toimplement some or all of the embodiments described herein; and

FIG. 11 depicts a block diagram of an embodiment of a computing device,in accordance with the embodiments described herein.

DETAILED DESCRIPTION

The present disclosure describes embodiments of form-fill-seal packagingsystems that include tracking systems to track locations of objects asthe objects are conveyed through the packaging systems. It may bedifficult to track the locations of objects in form-fill-seal packagingsystems in particular because the objects are inserted into a tube ofpackaging material that is then sealed and cut to form a package aroundthe objects. Sensors that rely on line-of-sight to detect the objects(e.g., cameras) are typically not able to detect the objects while theobjects are in the tube of packaging material and after the packages areformed around the object. In some examples described herein, thetracking system includes a controller that maintains a digital table oflocations of objects in the packaging system based on an initiallocation of the object before it entered the tube of the packagingmaterial and then adjusts the digital table of locations based on sensedmotion of a conveyance system in the packaging system.

As will be described in greater detail below, the ability of thetracking system to track the locations of objects as the objects areconveyed through the packaging system has a number of advantages. In oneexample, the packaging material used to form the tube and the packagesdoes not need to have regularly-spaced print marks to gage relativelocations of the packaging material and the objects. This lack ofregularly-spaced print marks improves the appearance of the finalpackages. In another example, the packaging material includesregularly-space graphic regions (e.g., a company's logo) on the exteriorof the package and the packaging system can control the location of theobjects with respect to the packaging material so that none of thegraphic regions are intersected by a seal or cut in the packagingmaterial when the packages are formed. In another example, the packagingsystem is able to control placement and/or printing of labels on theexterior of the packages based on the locations of the objects insteadof the locations of inducting documents placed on the objects. There area number of other benefits to the use of a tracking system in apackaging system, some of which are further described herein.

FIG. 1A depicts an embodiment of a packaging system 10. In the depictedembodiment, the packaging system 10 is a continuous flow wrap machine(e.g., a form-fill-seal wrapper). In other embodiments, the packagingsystem 10 is a non-continuous packaging system. In the depictedembodiment, the packaging system 10 includes a supply 18, a transferhead 20 including an inverting head 22, conveyors 24 ₁, 24 ₂, 24 ₃, and24 ₄ (collectively, conveyance system 24), a longitudinal sealer 26, anda sealing mechanism 28, as will be described in more detail herein.Examples of continuous flow wrap machines are described, for example, inU.S. Pat. No. 4,219,988, U.S. Patent Application No. 62/157,164, and PCTApplication No. PCT/US2016/030630, the contents of which areincorporated herein by reference in their entirety, and are availablefrom Sealed Air Corporation (Charlotte, N.C.) under the Shanklin FloWrapSeries trademark.

The supply 18 of the continuous flow wrap machine supplies a web ofpackaging material 30 from roll 32. In some embodiments, the packagingmaterial 30 is a polyethylene-based film. Systems for supplying webs ofpackaging material are known in art and may include unwind mechanismsand other features. In some embodiments, the packaging material 30 onthe roll 32 is a center folded film. In other embodiments, the packagingmaterial 30 on roll 32 is a flat wound film. In some embodiments, thepackaging material 30 includes any sheet or film material suitable forpackaging objects 36, in particular for packages 34 for use as a mailercontaining an object. Suitable materials include polymers, for examplethermoplastic polymers (e.g., polyethylene), that are suitable for heatsealing. In some embodiments, the packaging material 30 has a thicknessof any of at least 2, 3, 5, 7, 10, and 15 mils; and/or at most any of25, 20, 16, 12, 10, 8, 6 and 5 mils. In some embodiments, the packagingmaterial 30 is multilayered, and has an outer layer adapted for heatsealing the film to itself to form a seal.

The transfer head 20 of the packaging system 10 receives the web ofpackaging material 30 from the supply 18. The transfer head 20 isadapted to manage (e.g., form) the web of packaging material 30 into aconfiguration for eventual sealing into a tube. In the depictedembodiment, the transfer head 20 is an inverting head 22 of continuousflow wrap that receives a center folded web of packaging material 30from the supply 18 and redirects the web of film over the top and bottominverting head arms 40, 42 to travel in a conveyance direction 38 byturning the web of film inside out. In this manner, the transfer head 20is adapted to manage the web of packaging material 30 to provide aninterior space 44 bounded by the packaging material 30.

In some embodiments, the transfer head 20 in the configuration of aforming box receives the lay flat web of packaging material 30 from thesupply 18 and redirects the web of film over the forming head to travelin the conveyance direction 38 by turning the web of film inside out. Inthis manner, the transfer head 20 is adapted to manage the web ofpackaging material 30 to provide an interior space 44 bounded bypackaging material 30.

The infeed conveyor 24 ₁ of packaging system 12 is adapted to transporta series of objects 36 and sequentially deliver them in the conveyancedirection 38. In some embodiments, the infeed conveyor 24 ₁ is adaptedto convey a series of objects 36 that are non-uniformly spaced whenreceived by the conveyance system 24. In the embodiment depicted in FIG.1A, the objects 36 have a similar size. In other embodiments, theobjects have varied or differing sizes. Within the series of objects 36in sequential order, a “preceding” object is upstream from a “following”object. The infeed conveyor 24 ₁ is configured to deliver in repeatingfashion a preceding object upstream from a following object into theinterior space 44 of the web of packaging material 30. In someembodiments, the objects 36 are delivered in spaced or gappedarrangement from each other.

An “object,” as used herein, may comprise a single item for packaging,or may comprise a grouping of several distinct items where the groupingis to be in a single package. Further, an object may include anaccompanying informational item, such as a packing slip, tracking code,a manifest, an invoice, or printed sheet comprising machine-readableinformation (e.g., a bar code) for sensing by an object reader (e.g., abar code scanner).

Downstream from the infeed conveyor 24 ₁ is an infeed spacing conveyor24 ₂, which is adapted to convey objects by one or more infeed sensors.Downstream from the infeed spacing conveyor 24 ₂ is an object conveyor24 ₃, which is adapted to support and transport the web of packagingmaterial 30 and the object 36 downstream together to the sealingmechanism 28. A discharge conveyor 50 transports the series of packages34 from the sealing mechanism 28. In the depicted embodiment, thepackaging system 10 includes a sizing sensor 72 ₁, a spacing sensor 72₂, and an identifier sensor 72 ₃ (collectively infeed sensors 72). Thesizing sensor 72 ₁ is configured to determine one or more dimensions ofthe objects 36, such as a longitudinal length of the objects 36, aheight of the objects 36, or a transverse width of the objects 36. Thespacing sensor 72 ₂ is configured to determine a longitudinal spacingbetween consecutive objects 36. In some examples, the sizing sensor 72₁, the spacing sensor 72 ₂, and the identifier sensor 72 ₃ areconfigured to send signals to the controller or other computing device,and the controller or other computing device is configured to controlthe infeed spacing conveyor 24 ₂ and/or any other component of thepackaging system 10. In some embodiments, each of the infeed sensors 72includes one or more of an optical sensor (e.g., a visible light sensor,a laser sensor, or any other electromagnetic sensor), an RFID tagreader, a barcode reader, a camera, an acoustic sensor (e.g., anultrasonic sensor), a mechanical sensor (e.g., a plunger), or any othertype of sensor.

As each object 36 of the series of objects sequentially travels throughthe packaging system 12, its position within the machine is tracked.This is accomplished, for example, by an infeed eye system (horizontalor vertical) determining the location of the leading edge 52 of eachobject and the location of the trailing edge 54 of each object as theobject travels along the conveyance system 24. This location informationis communicated to a controller (e.g., a programmable logic controlleror “PLC”). A system of encoders and counters, also in communication withthe PLC, determines the amount of travel of the conveyor on which theobject is positioned. In this manner, the position of the object 36itself is determined and known by the PLC. The PLC is also incommunication with the sealing mechanism 28 to provide the objectposition information for a particular object.

In the depicted embodiment, the packaging system 10 includes alongitudinal sealer 26 adapted to continuously seal a longitudinal sideof the packaging material 30 together to form a tube 56 enveloping theobjects 36. In the depicted embodiment, the longitudinal sealer 26 islocated at one side of the tube 56, where the longitudinal sealers 26forms a side seal between two edge portions of the packaging material30. In other embodiments, another longitudinal sealer may be locatedbeneath the tube 56, where the sealer may form, for example, a centerfin seal between two edge portions of the web of packaging material 30.As two edge portions of packaging material 30 are brought together atthe longitudinal sealer 26 to form the tube 56, they are sealedtogether, for example, by a combination of heat and pressure, to form acontinuous fin or a side seal. Appropriate longitudinal sealers areknown in the art, and include, for example, heat sealers.

The packaging system 10 includes an sealing mechanism 28, which isadapted to provide or perform in repeating fashion, while the tube 56 istraveling: (i) a trailing edge seal 58 that is transverse to tube 56 andupstream from a preceding object to create package 34 and (ii) a leadingedge seal 60 transverse to the tube 56 and downstream from a followingobject. Further, the sealing mechanism 28 is adapted to sever thepackage 34 from the tube 56 by cutting between the trailing edge seal 58and the leading edge seal 60. Generally, the sealing mechanism 28 usestemperature and pressure to make two seals (trailing edge seal 58 andleading edge seal 60) and cuts between them, thus creating the final,trailing seal of one finished, preceding package and the first, leadingedge seal of the following package. Advantageously, the end sealer unitmay be adapted to simultaneously sever the package 34 from the tube 56while providing the trailing edge seal 58 and leading edge seal 60.

Useful end sealer units are known in the art. These include, forexample, rotary type of end sealer units, having matched heated barsmounted on rotating shafts. As the film tube passes through the rotarytype, the rotation is timed so it coincides with the gap betweenobjects. A double seal is produced and the gap between the two seals iscut by an integral blade to separate individual packs. Another type ofend seal unit is the box motion type, having a motion that describes a“box” shape so that its horizontal movement increases the contact timebetween the seal bars and the film. Still another type of end sealerunit is the continuous type, which includes a sealing bar that movesdown with the tube while sealing.

The packaging system 10 includes a labeling mechanism 76 that is capableof printing and/or applying labels 78 to exteriors of the packages 34.In some embodiments, the labels 78 include indications of the objects 36inside the packages 34, indications of shipping destinations of theobjects 36 inside the packages 34, and/or indications of ordersassociated with the objects 36 inside the packages 34. In someembodiments, the labeling mechanism 76 includes a printer that printsthe labels 78. In some cases, the printer prints the labels 78 directlyon the exterior of the packages 34. In other cases, the printer printsthe labels 78 on an adhesive medium and labeling mechanism 76 appliesthe adhesive medium to the exterior of the packages 34. In the depictedembodiment, the labeling mechanism 76 is located upstream of the sealingmechanism 28. In other embodiments, the labeling mechanism 76 can belocated downstream of the sealing mechanism 28.

In the depicted embodiment, the packaging system 10 includes a dischargescanner 74. The discharge scanner 74 is configured to scan one or moreof the packages 34 themselves, the labels 78 on the packages 34, orobject identifiers on the objects 36 inside of the packages 34. The datagenerated by the discharge scanner 74 may be used to verify that theobjects 36 have been wrapped in one of the packages 34. In someembodiments, the data generated by the discharge scanner 74 may becommunicated from the packaging system 10 to other systems that mayprocess the packages 34, as will be discussed in greater detail below.

The packaging system 10 also includes a controller 70. In the depictedembodiment, the controller 70 is in the form of a tablet with atouchscreen. In other embodiments, the controller 70 may be any othertype of computing device having any type of input and/or output devices.The controller 70 is configured to receive information from and/or sendcontrol signals to various individual components of the packaging system10. One embodiment of the operation of the controller 70 is depicted ina block diagram of portions of the packaging system 10 shown in FIG. 1B. As shown by the dashed lines in FIG. 1B, the controller 70 iscommunicatively coupled to each of the supply 18, the conveyors 24 ₁, 24₂, 24 ₃, and 24 ₄, the sealing mechanism 28, the infeed sensors 72, thedischarge scanner 74, and the labeling mechanism 76. The controller 70may not be communicatively coupled to every component in the packagingsystem 10 (e.g., the transfer head 20 and the longitudinal sealer 26 inthe depiction in FIG. 1B), especially where those components are passivecomponents that operate without any external control.

In some embodiments, the controller 70 is a part of a tracking systemconfigured to track locations of the objects 36 as the objects 36 areconveyed through the packaging system 10 on the conveyance system 24. Inparticular, the tracking system is configured to track locations of theobjects 36 before the objects 36 enter the tube 56, while the objects 36are in the tube 56, and after the packages 34 are formed by transverselycutting the tube 56. For example, the controller 70 can maintain adigital table of the objects 36 that are being conveyed through thepackaging system 10 along with an indication of the location of each ofthe objects 36 in the packaging system 10 at any given time. Thecontroller 70 changes the indications of the locations of each of theobjects 36 as the objects 36 are moved through the packaging system 10by the conveyance system 24. In this way, the controller 70 “knows”where every one of the objects 36 in the packaging system 10 is located,even when the objects 36 are located inside of the tube 56 and/or insideof one of the packages 34.

In existing packaging systems, the film has regularly-spaced printedmarks that serve as location markers. After an object enters a tube offilm or a package, the locations of the printed marks are tracked andthe location of the objects is estimated based on the location of theprinted marks on the film and the respective positions of the printedmarks and the object when the object entered the tube of film. However,using printed marks on the film to estimate the location of the objectcan be problematic because the objects can move relative to the filmwhile the objects are inside of the tube such that the object is nolonger in the same position with respect to the printed marks on thefilm.

In some embodiments, the tracking system in the packaging system 10 isconfigured to track locations of the objects 36 independently of anymarks on the packaging material. In some embodiments, the trackingsystem also includes at least one position detector in the infeedsensors 72 and at least one conveyor sensor (e.g., encoders on one ormore of the conveyors in the conveyance system 24). In some examples,the at least one conveyor sensor includes a plurality of encodersconfigured detect movements of each of a plurality of conveyor belts inthe conveyor system. The position detector detects an infeed location ofeach of the objects 36 at an infeed portion of the conveyance system 24(e.g., positions of leading edges of the objects 36 as they pass along aportion of the infeed spacing conveyor 242, positions of leading andtrailing edges of the objects 36 as they pass along a portion of theinfeed spacing conveyor 242) and communicate that information to thecontroller 70. The encoders detect motions of the conveyors in theconveyance system 24 and communicate that information to the controller70. The controller 70 maintains a location of each of the objects 36 inthe packaging system 10 based on the infeed location of the object 36read by the position detector and subsequent motions of the conveyors inthe conveyance system 24 as the conveyance system 24 moves the object36. In this manner, the locations of the objects 36 can be trackedindependently of any marks on the packaging material 30 even when theobjects 36 are in the tube 56 and/or in the packages 34.

In some embodiments, the infeed sensors 72 are configured to detectleading and trailing edges of the objects 36 as they pass along aportion of the infeed spacing conveyor 242. In some of theseembodiments, the tracking system (e.g., the infeed sensors 72 and/or thecontroller 70) is configured to calculate a longitudinal length of eachof the objects 36 based on the leading edge and the trailing edge ofeach of the objects 36. The tracking system of the packaging system 10may be further configured to cause the sealing mechanism 28 to seal thetube 56 of the packaging material 30 around one of the objects 36 atlocations based on physical characteristics of the objects 36, such asthe longitudinal length of the one of the objects 36. In some examples,the packaging system 10 is configured to cause the sealing mechanism 28to seal the tube 56 of the packaging material 30 around one of theobjects 36 at locations based on a combination of the longitudinallength of the one of the objects 36 and a height indication of the oneof the objects 36. As will be discussed in greater detail below, theheight indication of the one of the objects 36 may be generated by theinfeed sensors 72 as the objects 36 are fed through the infeed portionof the conveyance system 24, and the height indication may include atleast one of an indication whether any portion of the object 36 exceedsa predetermined height, an indication of a height of the leading edge ofthe object 36 and a height of the trailing edge of the object 36, or aheight profile of the object 36 from a transverse side of the object 36.

The controller 70 may be configured to function in a variety of ways tocontrol operations of the packaging system 10 based on informationreceived from components of the packaging system 10. In one example, thecontroller 70 receives information from the infeed sensors 72 aboutdimensions of the objects, sends control signals to the conveyancesystem 24 for properly conveying the objects, and sends control signalsto the sealing mechanism 28 for properly spacing transverse seals aroundthe objects. In another example of operation of the controller 70, thecontroller 70 receives information from the infeed sensors 72 aboutspacing of the objects, sends control signals to the conveyance system24 for properly conveying the objects, and sends control signals to thesupply 18 for properly advancing the packaging material 30. It will beapparent that the controller 70 can operate in any number of other waysto control operation of the packaging system 10.

Depicted in FIG. 2A is another embodiment of a packaging system 100 forcreating packages 102. The packaging system 100 includes a supply 104 ofpackaging material 106. In some embodiments, the packaging material 106is a cushion material, such as an inflated or an inflatable air cellularmaterial. In the depicted embodiment, the supply 104 is a roll of thepackaging material 106. In other embodiments, the supply 104 could besheets of the packaging material 106, fanfolded stacks of the packagingmaterial 106, or any other supply of the packaging material 106. In thedepicted embodiment, the packaging material 106 is a flexible sheetmaterial.

In some examples, the packaging material 106 is an inflated air cellularmaterial. As used herein, the term “air cellular material” herein refersto bubble cushioning material, such as BUBBLE WRAP® air cushioningmaterial sold by Sealed Air Corporation, where a first film or laminateis formed (e.g., thermoformed, embossed, calendared, or otherwiseprocessed) to define a plurality of cavities and a second film orlaminate is adhered to the first film or laminate in order to close thecavities. Examples of air cellular materials are shown in U.S. Pat. Nos.3,142,599, 3,208,898, 3,285,793, 3,508,992, 3,586,565, 3,616,155,3,660,189, 4,181,548, 4,184,904, 4,415,398, 4,576,669, 4,579,516,6,800,162, 6,982,113, 7,018,495, 7,165,375, 7,220,476, 7,223,461,7,429,304, 7,721,781, and 7,950,433, and U.S. Published PatentApplication Nos. 2014/0314978 and 2015/0075114, the disclosures of whichare hereby incorporated by reference in their entirety.

In some examples, the packaging material 106 is a foamed material.Methods for manufacturing such foamed materials are well known, asdisclosed in e.g., U.S. Pat. Nos. 5,348,984, 5,462,974, and 5,667,728,the contents of all of which are incorporated herein by reference intheir entirety. A common material used to form foamed materials is lowdensity polyethylene (LDPE). In some embodiments, foamed materials havea density ranging from about 0.5 to about 15 pounds/ft³. Foamedmaterials may be in the form of a sheet or plank having a thicknessranging from about 0.015 to about 5 inches. In producing the sheets offoamed materials, any conventional chemical or physical blowing agentsmay be used, such as a physical blowing agent (e.g., carbon dioxide,ethane, propane, n-butane, isobutane, pentane, hexane, butadiene,acetone, methylene chloride, any of the chlorofluorocarbons,hydrochlorofluorocarbons, hydrofluorocarbons, or any mixture thereof).If desired or necessary, various additives may also be included with thepolymer, such as a nucleating agent (e.g., zinc oxide, zirconium oxide,silica, talc, etc.) and/or an aging modifier (e.g., a fatty acid ester,a fatty acid amide, a hydroxyl amide, etc.).

In one particular embodiment, the supply 104 includes a roll of aninflatable web of air cellular material in a deflated state. As theinflatable web is unrolled, it is fed through an inflation and sealingmachine 108. The inflation and sealing machine 108 inflates and sealscells in the air cellular material so that the air cellular material isin an inflated state. In this embodiment, the packaging material 106 isthe inflated air cellular material. Examples of inflation and sealingmachines are described in U.S. Pat. No. 7,721,781 and U.S. PublishedPatent Application No. 2014/0314978, the contents of which are herebyincorporated by reference in their entirety.

The packaging material 106 has longitudinal edges 110. The packagingsystem 100 also includes a folding system 112. In the depictedembodiment, the folding system 112 includes two pairs of rollers:rollers 116 ₁ and rollers 116 ₂. In the depicted embodiment, the rollers116 ₁ are oriented vertically and the rollers 116 ₂ are oriented at anon-vertical and non-horizontal angle; however, the rollers 116 ₁ and116 ₂ could be oriented at any desired angle. The folding system 112folds the packaging material 106 from an unfolded state (e.g., the stateof the packaging material 106 when it is unrolled from the supply 104)into a tube 114 of the packaging material 106. In the tube 114 of thepackaging material 106, the longitudinal edges 110 of the packagingmaterial 106 are in an overlapping position.

In the depicted embodiment, each of the objects 120 includes an objectidentifier 122. In some examples, the object identifier includes one ormore of a barcode, a quick response (QR) code, a radio frequencyidentification (RFID) tag, any other form a machine-readableinformation, human-readable information, or any combination thereof.

The packaging system 100 also includes a conveyance system 124 that isconfigured to feed objects 120 and/or the packaging material 106. In thedepicted embodiment, the conveyor system includes an infeed conveyor 124₁, an infeed spacing conveyor 124 ₂, a machine conveyor 124 ₃, and anend conveyor 124 ₄ (collectively conveyance system 124). The infeedconveyor 124 ₁ is configured to feed the objects 120. The objects 120are at an uncontrolled spacing on the infeed conveyor 124 ₁. The infeedspacing conveyor 124 ₂ is configured to feed the objects 120 after theyleave the infeed conveyor 124 ₁. The infeed spacing conveyor 124 ₂ isconfigured to be controlled by a controller or other computing device(not shown) to provide a particular spacing between the objects 120. Inthe depicted embodiment, the packaging system 100 includes a sizingsensor 132 ₁, a spacing sensor 132 ₂, and an identifier sensor 132 ₃(collectively infeed sensors 132). The sizing sensor 132 ₁ is configuredto determine one or more dimensions of the objects 120, such as alongitudinal length of the objects 120, a height of the objects 120, ora transverse width of the objects 120. The spacing sensor 132 ₂ isconfigured to determine a longitudinal spacing between consecutiveobjects 120. In some examples, the sizing sensor 132 ₁, the spacingsensor 132 ₂, and the identifier sensor 132 ₃ are configured to sendsignals to the controller or other computing device, and the controlleror other computing device is configured to control the infeed spacingconveyor 124 ₂ and/or any other component of the packaging system 100.In some embodiments, each of the infeed sensors 132 includes one or moreof an optical sensor (e.g., a visible light sensor, a laser sensor, orany other electromagnetic sensor), an RFID tag reader, a barcode reader,a camera, an acoustic sensor (e.g., an ultrasonic sensor), a mechanicalsensor (e.g., a plunger), or any other type of sensor.

As shown in FIG. 2, the packaging material 106 is configured to be fedover the machine conveyor 124 ₃ so that the objects 120 are fed onto thepackaging material 106. The machine conveyor 124 ₃ supports and feedsboth the packaging material 106 and the objects 120. In the depictedembodiment, the objects 120 are fed onto the packaging material 106while the packaging material 106 is in an unfolded state (e.g., beforethe longitudinal edges 110 are in the overlapping position). Theconveyance system 124 is configured to feed the objects 120 onto thepackaging material 106 so that the tube 114 of the packaging material106 is formed around the objects 120.

In the depicted embodiment, the packaging system 100 includes a holdingmechanism 138 configured to hold the longitudinal edges 110 in theoverlapping position as the packaging material 106 is fed between thefolding system 112 and a sealing mechanism 140. In some embodiments, theholding mechanism 138 includes a roller 142 located above thelongitudinal edges 110 in the overlapping position, and the roller 142holds the longitudinal edges 110 in the overlapping position after thepackaging material 106 has been folded. In some embodiments, the holdingmechanism 138 includes an overhead conveyor 144 that has a hangingunderside 146. The hanging underside 146 is configured to contact thetube 114 of the packaging material 106 where the longitudinal edges 110are in the overlapping position. In some embodiments, such as theembodiment depicted in FIG. 2A, the holding mechanism 138 includes boththe roller 142 and the overhead conveyor 144.

The sealing mechanism 140 is configured to provide or perform, inrepeating fashion, while the tube 114 is traveling: (i) a leading edgeseal 148 that is transverse to tube 114, (ii) a trailing edge seal 150transverse to the tube 114, and (iii) a transverse cut between theleading edge seal 148 and the trailing edge seal 150. Each of theleading edge seal 148 and the trailing edge seal 150 seals the packagingmaterial 106 with the longitudinal edges 110 in the overlappingposition. Preferably, one or more of the objects 120 are located insideof each of the packages 102 between one of the leading edge seals 148and one of the leading trailing edge seals 150. In some embodiments, thesealing mechanism 140 uses temperature and/or pressure to make twotransverse seals (leading edge seal 148 and trailing edge seal 150) andtransversely cuts between them. These transverse cuts create packages102 separated from the tube 114 of the packaging material 106.Advantageously, the sealing mechanism 140 may be adapted tosimultaneously sever the packages 102 from the tube 114 while formingthe leading edge seal 148 and trailing edge seal 150.

Various forms of sealing mechanisms 140 are known in the art. Theseinclude, for example, rotary end sealer units that have matched heatedbars mounted on rotating shafts. As the film tube passes through therotary type, the rotation is timed so it coincides with the gap betweenproducts. A double seal is produced and the gap between the two seals iscut by an integral blade to separate individual packages. Another typeof sealing mechanisms 140 is the box motion type, having a motion thatdescribes a “box” shape so that its horizontal movement increases thecontact time between the seal bars and the film. Still another type ofsealing mechanisms 140 is the continuous type, which includes a sealingbar that moves down with the tube 114 while sealing. In some cases, thepackaging system 100 feeds packaging material 106 from the supply 104intermittently in order to form packages 102 intermittently. In thesecases, the sealing mechanisms 140 may not need to move in a downstreamdirection to form the transverse seals and cuts. In other cases, thepackaging system 100 feeds packaging material 106 from the supply 104continuously in order to form packages 102 continuously. In these cases,the sealing mechanisms 140 may move in a downstream direction whileforming the transverse seals and cuts.

The packaging system 100 includes a labeling mechanism 152 that iscapable of applying labels 154 to exteriors of the packages 102. In someembodiments, the labels 154 include indications of the objects 120inside the packages 102, indications of shipping destinations of theobjects 120 inside the packages 102, and/or indications of ordersassociated with the objects 120 inside the packages 102. In someembodiments, the labeling mechanism 152 includes a printer that printsthe labels 154. In some cases, the printer prints the labels 154directly on the exterior of the packages 102. In other cases, theprinter prints the labels 154 on an adhesive medium and labelingmechanism 152 applies the adhesive medium to the exterior of thepackages 102. In the depicted embodiment, the labeling mechanism 152 islocated downstream of the sealing mechanism 140. In other embodiments,the labeling mechanism 152 can be located upstream of the sealingmechanism 140.

In the depicted embodiment, the packaging system 100 includes adischarge scanner 158. The discharge scanner 158 is configured to scanone or more of the packages 102 themselves, the labels 154 on thepackages 102, or the object identifiers 122 on the objects 120 insidesof the packages 102. The data generated by the discharge scanner 158 maybe used to verify that the objects 120 have been wrapped in one of thepackages 102. In some embodiments, the data generated by the dischargescanner 158 may be communicated from the packaging system 100 to othersystems that may process the packages 102, as will be discussed ingreater detail below.

The packaging system 100 also includes a controller 160. In the depictedembodiment, the controller 160 is in the form of a tablet with atouchscreen. In other embodiments, the controller 160 may be any othertype of computing device having any type of input and/or output devices.The controller 160 is configured to receive information from and/or sendcontrol signals to various individual components of the packaging system100. One embodiment of the operation of the controller 160 is depictedin a block diagram of portions of the packaging system 100 shown in FIG.2B. As shown by the dashed lines in FIG. 2B the controller 160 iscommunicatively coupled to each of the supply 104, the conveyors 124 ₁,124 ₂, 124 ₃, and 124 ₄, the sealing mechanism 140, the infeed sensors132, the discharge scanner 158, and the labeling mechanism 152. Thecontroller 160 may not be communicatively coupled to every component inthe packaging system 100 (e.g., the folding system 112 in the depictionin FIG. 2B), especially where those components are passive componentsthat operate without any external control.

In some embodiments, the controller 160 is a part of a tracking systemconfigured to track locations of the objects 120 as the objects 120 areconveyed through the packaging system 100 on the conveyance system 124.In particular, the tracking system is configured to track locations ofthe objects 120 before the objects 120 enter the tube 114, while theobjects 120 are in the tube 114, and after the packages 102 are formedby transversely cutting the tube 114. For example, the controller 160can maintain a table of the objects 120 that are being conveyed throughthe packaging system 100 along with an indication of the location ofeach of the objects 120 in the packaging system 100. The controller 160changes the indications of the locations of each of the objects 120 overtime as the objects 120 are moved through the packaging system 100 bythe conveyance system 124. In this way, the controller 160 “knows” whereevery one of the objects 120 in the system is located, even when theobjects 120 are located inside of the tube 114 and/or inside of one ofthe packages 102.

In some embodiments, the tracking system in the packaging system 100 isconfigured to track locations of the objects 120 independently of anymarks on the packaging material. In some embodiments, the trackingsystem also includes at least one position detector in the infeedsensors 132 and at least one conveyor sensor (e.g., encoders on one ormore of the conveyors in the conveyance system 124). In some examples,the at least one conveyor sensor includes a plurality of encodersconfigured detect movements of each of a plurality of conveyor belts inthe conveyor system. The position detector detects an infeed location ofeach of the objects 120 at an infeed portion of the conveyance system124 (e.g., positions of leading edges of the objects 120 as they passalong a portion of the infeed spacing conveyor 124 ₂, positions ofleading and trailing edges of the objects 120 as they pass along aportion of the infeed spacing conveyor 124 ₂) and communicate thatinformation to the controller 160. The encoders detect motions of theconveyors in the conveyance system 124 and communicate that informationto the controller 160. The controller 160 maintains a location of eachof the objects 120 in the packaging system 100 based on the infeedlocation of the object 120 read by the position detector and subsequentmotions of the conveyors in the conveyance system 124 as the conveyancesystem 124 moves the object. In this manner, the locations of theobjects 120 can be tracked even when the objects 120 are in the tube 114and/or in the packages 102 independently of any marks on the packagingmaterial 106.

In some embodiments, the infeed sensors 132 are configured to detectleading and trailing edges of the objects 120 as they pass along aportion of the infeed spacing conveyor 124 ₂. In some of theseembodiments, the tracking system (e.g., the infeed sensors 132 and/orthe controller 160) is configured to calculate a longitudinal length ofeach of the objects 120 based on the leading edge and the trailing edgeof each of the objects 120. The tracking system of the packaging system100 may be further configured to cause the sealing mechanism 140 to sealthe tube 114 of the packaging material 106 around one of the objects 120at locations based on physical characteristics of the one of the objects120, such as the longitudinal length of the one of the objects 120. Insome examples, the packaging system 100 is configured to cause thesealing mechanism 140 to seal the tube 114 of the packaging material 106around one of the objects 120 at locations based on a combination of thelongitudinal length of the one of the objects 120 and a heightindication of the one of the objects 120. As will be discussed ingreater detail below, the height indication of the one of the objects120 may be generated by the infeed sensors 132 as the objects 120 arefed through the infeed portion of the conveyance system 124, and theheight indication may include at least one of an indication whether anyportion of the object 120 exceeds a predetermined height, an indicationof a height of the leading edge of the object 120 and a height of thetrailing edge of the object 120, or a height profile of the object 120from a transverse side of the object 120.

The controller 160 may be configured to function in a variety of ways tocontrol operations of the packaging system 100 based on informationreceived from components of the packaging system 100. In one example,the controller 160 receives information from the infeed sensors 132about dimensions of the objects, sends control signals to the conveyancesystem 124 for properly conveying the objects, and sends control signalsto the sealing mechanism 140 for properly spacing transverse sealsaround the objects. In another example of operation of the controller160, the controller 160 receives information from the infeed sensors 132about spacing of the objects, sends control signals to the conveyancesystem 124 for properly conveying the objects, and sends control signalsto the supply 104 for properly advancing the packaging material 106. Itwill be apparent that the controller 160 can operate in any number ofother ways to control operation of the packaging system 100.

As noted above with respect to both the packaging system 10 and thepackaging system 100, an infeed scanner can detect a longitudinal lengthand/or a height indication of each object at an infeed portion of aconveyance system. In some embodiments, the height indication for anobject includes at least one of an indication whether any portion of theobject exceeds a predetermined height, an indication of a height of theleading edge of the object and a height of the trailing edge of theobject, or a height profile of the object from a transverse side of theobject. These embodiments of height indications are depicted in FIGS.3A-3D, FIGS. 4A-4D, and FIGS. 5A-5D.

In FIGS. 3A-3D, FIGS. 4A-4D, and FIGS. 5A-5D, a system 200 determines aheight indication of an object 210 that has a leading edge 212 and atrailing edge 214. In the depicted embodiment, the object 210 is a casefor a musical instrument; however, the object 210 may be another othertype of object or groups of objects. The system 200 includes aconveyance system 220. In the depicted embodiment, the conveyance system220 includes a first conveyor 222 and a second conveyor 224. Theconveyance system 220 may also include additional conveyors. In someembodiments, the conveyance system 220 may be configured to receiveobjects (including the object 210) that are non-uniformly spaced ontothe first conveyor 222. The first and second conveyors 222 and 224 maybe controlled independently to control the spacing between the objectsas the objects are moved from the first conveyor 222 to the secondconveyor 224.

The system 200 includes an infeed scanner 230. In some embodiments, theinfeed scanner 230 includes one or more of an optical sensor (e.g., avisible light sensor, a laser sensor, or any other electromagneticsensor), an RFID tag reader, a barcode reader, a camera, an acousticsensor (e.g., an ultrasonic sensor), a mechanical sensor (e.g., aplunger), or any other type of sensor. In the depicted embodiment, theinfeed scanner 230 is arranged in a transverse direction across theconveyance system 220, substantially perpendicular to the direction ofmovement of objects on the conveyance system 220. As objects pass by theinfeed scanner 230, the infeed scanner 230 is capable of detecting oneor more of the leading edge 212 of the object 210, the trailing edge 214of the object 210, or a height of the object 210 at any point betweenthe leading edge 212 and the trailing edge 214.

In the embodiment depicted in FIGS. 3A-3D, the infeed scanner 230 isconfigured to detect whether any portion of an object exceeds apredetermined height 232 (depicted as a dotted line in FIGS. 3A-3D). Atthe instance depicted in FIG. 3A, the leading edge 212 of the object 210is at the infeed scanner 230. The infeed scanner 230 can detect theleading edge 212 of the object 210 and begin detecting whether anyportion of the object 210 exceeds the predetermined height 232. At theinstance depicted in FIG. 3A, the height of the object 210 does notexceed the predetermined height 232. As the object 210 is moved forwardby the conveyance system 220 from the instance depicted in FIG. 3A tothe instance depicted in FIG. 3B, the height of the object 210 stilldoes not exceed the predetermined height 232.

As the object 210 is moved forward by the conveyance system 220 from theinstance depicted in FIG. 3B to the instance depicted in FIG. 3C, theheight of the object 210 does exceed the predetermined height 232. Atthat point, the infeed scanner 230 may generate a height indication thatat least a portion of the object 210 exceeds the predetermined height232. This height indication can be communicated to a controller (e.g.,the controller 70, the controller 160, or any other computing device)for controlling placement of the object 210 in a tube of film orpackaging material, controlling locations of transverse seals in thefilm or packaging material around the object 210, or controlling anyother function of a packaging system.

The object 210 continues to be moved by the conveyance system 220 fromthe instance depicted in FIG. 3C to the instance depicted in FIG. 3D. InFIG. 3D, the trailing edge 214 of the object 210 is at the infeedscanner 230 and the infeed scanner 230 stops detecting whether anyportion of the object 210 exceeds the predetermined height 232. Theheight of the trailing edge 214 does not exceed the predetermined height232. Even though the height of the trailing edge 214 does not exceed thepredetermined height 232, the height indication for the object 210remains that at least a portion of the object 210 exceeds thepredetermined height 232. In some embodiments, the infeed scanner 230 iscapable of determining a longitudinal length of the object 210 based onthe distance between the leading edge 212 and the trailing edge 214. Theinfeed scanner 230 may communicate the longitudinal length to acontroller (e.g., the controller 70, the controller 160, or any othercomputing device) for controlling placement of the object 210 in a tubeof film or packaging material, controlling locations of transverse sealsin the film or packaging material around the object 210, controlling anyother function of a packaging system. In some embodiments, thecontroller is configured to control any of the functions of thepackaging system based on a combination of the longitudinal length andthe height indication.

In the embodiment depicted in FIGS. 4A-4D, the infeed scanner 230 isconfigured to detect an indication of a height of the leading edge 212of the object 219 and a height of the trailing edge 214 of the object210. At the instance depicted in FIG. 4A, the leading edge 212 of theobject 210 is at the infeed scanner 230. The infeed scanner 230 detectsthe leading edge 212 of the object 210 and the height 234 of the object210 at the leading edge 212. The object 210 is moved forward by theconveyance system 220 from the instance depicted in FIG. 4A. As theobject 210 passes the instances depicted in FIGS. 4B and 4C, the infeedscanner 230 does not record any height of the object 210. In theinstance depicted in FIG. 4D, the trailing edge 214 of the object 210 isat the infeed scanner 230. The infeed scanner 230 detects the trailingedge 214 of the object 210 and the height 236 of the object 210 at thetrailing edge 214.

The infeed scanner 230 is capable of generating a height indication thatincludes an indication of the height 234 of the leading edge 212 and theheight 236 of the trailing edge 214. The infeed scanner 230 is alsocapable of determining a longitudinal length of the object 210 based onthe distance between the leading edge 212 and the trailing edge 214. Theheight indication and/or the longitudinal length can be communicated toa controller (e.g., the controller 70, the controller 160, or any othercomputing device) for controlling placement of the object 210 in a tubeof film or packaging material, controlling locations of transverse sealsin the film or packaging material around the object 210, or controllingany other function of a packaging system.

In the embodiment depicted in FIGS. 5A-5D, the infeed scanner 230 isconfigured to detect a height profile of the object 210 from atransverse side of the object 210. At the instance depicted in FIG. 5A,the leading edge 212 of the object 210 is at the infeed scanner 230. Theinfeed scanner 230 detects the height of the leading edge 212 and adds apoint to the height profile indicative of the height of the leading edge212. A depiction of the height profile up until the instance shown inFIG. 5A is depicted in the chart 240 that is also shown in FIG. 5A. Theobject 210 is moved forward by the conveyance system 220 from theinstance depicted in FIG. 5A. At various times, as the object 210 passesthe instances depicted in FIGS. 5B and 5C, the infeed scanner 230periodically determines heights of the object 210 from the transverseside of the object 210. Depictions of the height profiles up until theinstances shown in FIGS. 5B and 5C are depicted, respectively, in thecharts 242 and 244 that are also shown in FIGS. 5B and 5C.

In the instance depicted in FIG. 5D, the trailing edge 214 of the object210 is at the infeed scanner 230. The infeed scanner 230 detects theheight of the trailing edge 214 of the object 210. A depiction of theheight profile up until the instance shown in FIG. 5D is depicted in thechart 246 that is also shown in FIG. 5D. As can be seen by the chart246, the height profile of the object 210 forms an outline of the object210 from a transverse side of the object 210. In the depictedembodiment, the indications of the heights in FIG. 5D areuniformly-spaced along the longitudinal length of the object. Theresolution of the data points (e.g., the spacing between data points inthe chart 246) can be selected or adjusted as desired. In otherembodiments, the data points in a height profile can benon-uniformly-spaced. While the height profile generated during theprocess shown from FIG. 5A to FIG. 5D is in the form of charts 240, 242,244, and 246, it will be apparent that the height profile data can begenerated in any form, such as sets of Cartesian coordinate points, setsof polar coordinate points, or any other manner of defining points in atwo- or three-dimensional space.

The infeed scanner 230 is capable of communicating the heightindication, including the height profile depicted in the chart 246, to acontroller (e.g., the controller 70, the controller 160, or any othercomputing device). The controller can determine any number ofcharacteristics of the object 210 from the height profile. For example,the controller can determine one or more of a longitudinal length of theobject 210, a height of the object 210 at any particular longitudinalposition of the object 210, a contour or slope of the object 210 nearthe leading edge 212 and/or the trailing edge 214, an average height ofthe object 210, or any other characteristic of the object 210. Thecontroller is capable of controlling any function of a packaging systembased at least on one or more of the characteristics determined from theheight profile. For example, the controller can control one or more ofplacement of the object 210 in a tube of film or packaging material,locations of transverse seals in the film or packaging material aroundthe object 210, or any other function of a packaging system based atleast on one or more of the characteristics determined from the heightprofile.

In some instances packaging material used in a form-fill-seal packagingsystems can include intermittently-spaced graphic regions. Theseintermittently-spaced graphic regions can include a combination of textand images, such as a logo, a word mark, a trademark, a word, a name, apicture, or any combination thereof. For example, when theform-fill-seal packaging system is used to package objects that are soldby a company for shipment to the company's customers, each of theintermittently-spaced graphic regions can include the company's logo,the company's name, and/or the company's slogan. The spacing of theseintermittent graphic regions can be selected such that, as packages areformed from the packaging material, one or more of the graphic regionswill typically be visible on the exterior of the package to identify theseller. For example, the graphic regions can be spaced at intervals of15 inches. In this example, the form-fill-seal packaging system may alsobe configured to make packages of not less than 15 inches in length,thereby assuring that at least a portion of one of the graphic regionsis located on the outer side of packages formed from the packagingmaterial.

FIG. 6A depicts an example of a packaging system 10′ that uses apackaging material 30′ having intermittently-spaced graphic regions 80to form packages 34. Aside from those aspects, the packaging system 10′is substantially similar to the packaging system 10. As can be seen inFIG. 6A, after the packaging material 30′ is inverted to form the tube56, the graphic regions 80 are on the exterior of the tube 56. Thegraphic regions 80 are intermittently-spaced in a longitudinal directionof the packaging material 30′. In addition, as the packages 34 areformed, the graphic regions 80 remain on the exterior of the packages34.

FIG. 6B depicts some of the difficulties with the use of the packagingmaterial 30′ with the intermittently-spaced graphic regions 80. In thisexample, the object 36 is in the form of a hockey stick and each of thegraphic regions 80 includes a name and logo of a hockey gear company. Asthe sealing mechanism 28 (not shown in FIG. 6B) formed the leading seal60 and the trailing seal 58 to form the package 34, each of the leadingseal 60 and the trailing seal 58 intersected the one of the graphicregions 80. In addition, the label 78 applied by the labeling mechanism76 (not shown in FIG. 6B) covers one of the graphic regions 80. Thus,even though a portion of each of three of the graphic regions 80 islocated on the package 34, none of the graphic regions 80 on theexterior of the package 34 is whole and entirely visible. This reducesthe benefit of having the graphic regions 80 on the exterior of thepackage 34.

As described above, embodiments of tracking systems described hereininclude a controller that tracks the locations of the objects beingconveyed by a conveyance system and controls functions of the packagingsystem based on the locations of the objects in the packaging system. Insome embodiments, the controller controls the placement of the objectsin the tube of the packaging material and/or the feeding of thepackaging material such that the objects are located at particularlocations with respect to the packaging material so that transverse cutsand seals are made in the packaging material without intersecting thegraphic regions. In some embodiments, the controller controls operationof the sealing mechanism that forms transverse seals and cuts in thetube of the film so that transverse cuts and seals are made in thepackaging material without intersecting the graphic regions. In someembodiments, the controller controls operation of the labeling mechanismto cause labels to be placed on the packaging material so that thelabels do not overlap any of the graphic regions.

FIG. 6C depicts an embodiment of a package 34 formed so that graphicregions are not intersected or covered by seals, cuts, or labels. In thedepicted embodiment, the location of the object 36 with respect to thepackaging material 30′ and/or the operation of the longitudinal sealer26 was controlled so that the leading seal 60 and the trailing seal 58do not intersect any of the graphic regions 80. In addition, theoperation of the labeling mechanism was controlled so that the label 78was placed in a location that does not overlap any of the graphicregions 80. In this way, the resulting package 34 includes two graphicregions 80 that are not intersected or covered by seals, cuts, orlabels.

Another difficulty with form-fill-seal packaging systems is the handlingof flawed packages. Packages can be flawed if the package lacks one ofthe objects that should be in the package, the package includes an extraobject that should not be in the package, a label on the package cannotbe read, the package lacks a label, the package has an improperdimension, a transverse seal on the package intersects a graphic region,a user input indicates that the package is flawed, any other flaw, orany combination thereof. If a flawed package is created, it may not bepossible for an operator of the packaging system to know that thepackage is flawed without opening the package to see what object orobjects are inside of the package. To address this issue, whentraditional form-fill-seal packaging systems detect a flawed package,the packaging system stops all operation and signals an alert that thepackaging system has identified a flaw. This alert signals an operatorto investigate the flaw and either fix the flaw or remove the objectsassociated with the flawed package. After the person addresses the flaw,the person can restart the packaging machine. The result is that noflawed packages are created. However, this signaling of the alert alsohas drawbacks in the amount of downtime of the packaging system whilethe operator is addressing the flaw. If no operator is available toaddress the flaw immediately, there could be a significant amount ofdown time for the packaging machine.

In the embodiment of packaging systems described herein that tracklocations of the objects, the tracked locations of the object can beused when a flawed package is detected. In particular, the packagingsystems can be configured to pass packages to a downstream packagehandling system and to communicate, to the downstream package handlingsystem, the location of the objects and an indication whether thepackage is flawed. An example of a downstream package handling system300 is depicted in embodiments of systems shown in FIGS. 7A and 7B,which depict, respectively, a system 310 that includes the packagingsystem 10 and the downstream package handling system 300 and a system320 that includes the packaging system 100 and the downstream packagehandling system 300.

The downstream package handling system 300 includes conveyors 302 ₁, 302₂, 302 ₃, and 302 ₄ (collectively, conveyance system 302). Theconveyance system 302 is configured to receive packages and to conveythey packages through the downstream package handling system 300. Thedownstream package handling system 300 also includes routing elements304 ₁ and 304 _(M) (collectively routing system 304). The routingelements 304 ₁ and 304 _(M) are selectively operable to selectivelyroute the packages along various paths through the downstream packagehandling system 300. The routing elements 304 ₁ and 304 _(M) may begates, as depicted in FIGS. 7A and 7B, directional rollers, conveyorbelts, doors, robotic arms, or any other element capable of selectivelyrouting the packages.

The downstream package handling system 300 also includes packagedestinations 306 ₁, 306 ₂, and 306 _(N) (collectively packagedestinations 306). The package destinations 306 are destinations for thepackages that have been routed through the downstream package handlingsystem 300 by the routing system 304. In some embodiments, the packagedestinations 306 are bins configured to hold a number of packages thatare intended for different handling. For example, the packagedestination 306 ₁ may be a bin designated to hold packages that aredeemed to be flawed, the package destination 306 ₂ may be a bindesignated to hold packages that will be shipped by a first shippingcompany, and the package destination 306 _(N) may be a bin designated tohold packages that will be shipped by a second shipping company. In thisway, the different types of packages are separated and collected in anappropriate holding bin at the package destinations 306. In otherembodiments, the package destinations 306 are outfeed conveyorsconfigured to route the packages for further handling. For example, thepackage destination 306 ₂ may be an outfeed conveyor that routespackages to a transportation vehicle of a first shipping company, andthe package destination 306 _(N) may be an outfeed conveyor that routespackages to a transportation vehicle of a second shipping company. Itwill be understood that the downstream package handling system 300 caninclude any number of conveyors in the conveyance system 302, any numberof routing elements in the routing system 304, and any number of thepackaging destinations 306.

The downstream package handling system 300 also includes a controller308. The controller 308 is communicatively coupled to each of therouting elements 304 ₁ and 304 _(M) in the routing system 304. Thecontroller 308 is configured to send control signals to the routingsystem 304 to control operation of each of the routing elements 304 ₁and 304 _(M) in the routing system 304. In this way, the controller 308is able to control which packages arrive at particular packagedestinations 306. In some embodiments, the controller 308 is configuredto send control signals based on user inputs. In other examples, as willbe discussed in greater detail below, the controller 308 is configuredto send control signals based on information received from a packagingsystem.

In FIG. 7A, the system 310 includes the packaging system 10 and thedownstream package handling system 300. The system 310 is configured toconvey objects and packages in a direction 312. More specifically, thepackaging system 10 is configured to receive objects and to formpackages around the objects, and the downstream package handling system300 is configured to receive the packages and to sort the packages tothe different package destinations 306. The system optionally includesan intermediate conveyor 314 between the conveyance system 24 of thepackaging system 10 and the conveyance system 302 of the downstreampackage handling system 300. The intermediate conveyor 314 may beconfigured to convey packages exiting the packaging system 10 and conveythe packages to an infeed location of the downstream package handlingsystem 300. In other embodiments, the system 310 does not include theintermediate conveyor 314 and the conveyor 24 ₄ is configured to passthe packages directly to the conveyor 302 ₁.

In the despite embodiment, the system 310 also includes a network 316.The network 316 may be a wired network, a wireless network, or anycombination of wired and wireless networks. In other embodiments, thenetwork 316 may be replaced by a direct communication link, such as awired serial communication line, a wireless Bluetooth connection, acommunication bus, or any other direct communication link. Thecontroller 70 of the packaging system 10 is communicatively coupled tothe network 316. The controller 308 of the downstream package handlingsystem 300 is also communicatively coupled to the network 316. Thecontroller 70 and the controller 308 are capable of communicatinginformation to each other via the network 316.

In some embodiments, the controller 70 is configured to determinewhether any of the packages formed by the packaging system is flawed. Asnoted above, a package can be deemed to be flawed if the package lacksone of the objects that should be in the package, the package includesan extra object that should not be in the package, a label on thepackage cannot be read, the package lacks a label, the package has animproper dimension, a transverse seal on the package intersects agraphic region, a user input indicates that the package is flawed, anyother flaw, or any combination thereof. If the controller 70 determinesthat one of the packages is flawed, the controller 70 can communicate tothe controller 308, via the network 316, an indication that the packageis flawed. The controller 308 is configured to sort flawed packages fromother packages that are not flawed based at least on the location of thepackage and the indication that the package is flawed received from thecontroller 70.

In FIG. 7B, the system 320 includes the packaging system 100 and thedownstream package handling system 300. The system 320 is configured toconvey objects and packages in a direction 322. More specifically, thepackaging system 100 is configured to receive objects and to formpackages around the objects, and the downstream package handling system300 is configured to receive the packages and to sort the packages tothe different package destinations 306. The system optionally includesan intermediate conveyor 324 between the conveyance system 124 of thepackaging system 100 and the conveyance system 302 of the downstreampackage handling system 300. The intermediate conveyor 314 may beconfigured to convey packages exiting the packaging system 100 andconvey the packages to an infeed location of the downstream packagehandling system 300. In other embodiments, the system 320 does notinclude the intermediate conveyor 324 and the conveyor 124 ₄ isconfigured to pass the packages directly to the conveyor 302 ₁.

In the depicted embodiment, the system 320 also includes a network 326.The network 326 may be a wired network, a wireless network, or anycombination of wired and wireless networks. In other embodiments, thenetwork 326 may be replaced by a direct communication link, such as awired serial communication line, a wireless Bluetooth connection, acommunication bus, or any other direct communication link. Thecontroller 160 of the packaging system 10 is communicatively coupled tothe network 326. The controller 308 of the downstream package handlingsystem 300 is also communicatively coupled to the network 326. Thecontroller 160 and the controller 308 are capable of communicatinginformation to each other via the network 326.

In some embodiments, the controller 160 is configured to determinewhether any of the packages formed by the packaging system is flawed. Asnoted above, a package can be deemed to be flawed if the package lacksone of the objects that should be in the package, the package includesan extra object that should not be in the package, a label on thepackage cannot be read, the package lacks a label, the package has animproper dimension, a transverse seal on the package intersects agraphic region, a user input indicates that the package is flawed, anyother flaw, or any combination thereof. If the controller 160 determinesthat one of the packages is flawed, the controller 160 can communicateto the controller 308, via the network 326, an indication that thepackage is flawed. The controller 308 is configured to sort flawedpackages from other packages that are not flawed based at least on thelocation of the package and the indication that the package is flawedreceived from the controller 160.

The embodiments of the systems 310 and 320 shown in FIGS. 7A and 7Binclude one packaging system—either packaging system 10 or packagingsystem 100—upstream from the downstream package handling system 300. Inother embodiments, multiple packaging systems may be located upstream ofthe downstream package handling system 300. In one embodiment, a systemcan include the packaging system 100, the packaging system 10, and thedownstream package handling system 300, all of which are communicativelycoupled to each other via one or more networks. The packaging system 100is capable of receiving objects that are non-uniformly spaced, formingcushion packages around the objects, and passing the cushion packages tothe packaging system 10. The controller 160 is capable of communicatinginformation about the cushion packages (e.g., locations of the cushionpackages) to the controller 70 of the packaging system 10. The packagingsystem 10 is capable of receiving the cushion packages, forming packagesaround the cushion packages, and passing the packages to the downstreampackage handling system 300. The controller 70 is capable ofcommunicating information about the packages (e.g., locations of thepackages) to the controller 308 of the downstream package handlingsystem 300. The downstream package handling system 300 is capable ofpackages based at least on the information received from one or both ofthe controllers 70 and 160. In some embodiments, one or both of thecontrollers 70 and 160 can determine that one of the packages is flawedand communicate that to the controller 308 so that the controller 308can cause the flawed package to be sorted from the packages that are notflawed.

As described above, embodiments of packaging systems described hereinare capable of tracking locations of objects as the objects are conveyedthrough the packaging systems. The ability to track the locations ofobjects can aid in placement of labels on packages after the packagesare formed around the objects. Existing systems rely on the properplacement of inducting documents on objects for the packaging system toproperly locate a label on packages. An example of this type of systemand some of the drawbacks associated therewith are depicted in FIGS. 8Ato 8C. In the systems described herein, the ability of the packagingsystem to track locations of the objects may eliminate the need to relyon the proper placement of inducting documents. An example of this typeof system and some of the benefits associated therewith are depicted inFIGS. 9A to 9C.

FIGS. 8A and 8B depict two instances of an infeed portion of a packagingsystem 400. The packaging system 400 includes a conveyance system 424that conveys objects 436 ₁, 436 ₂, 436 ₃, 436 ₄, and 436 ₅(collectively, objects 436). Each of the objects 436 includes,respectively, a leading edge 452 ₁, 452 ₂, 452 ₃, 452 ₄, and 452 ₅(collectively, leading edges 452) and a trailing edge 454 ₁, 454 ₂, 454₃, 454 ₄, and 454 ₅ (collectively, trailing edges 454). The conveyancesystem 424 is configured convey the objects 436 in a conveyancedirection 438. As the objects 436 are conveyed by the conveyance system424, the objects 436 pass by an infeed scanner 472. The infeed scanner472 is arranged to scan for identifiers at a particular transverselocation on the conveyance system 424.

Each of the objects 436 ₁, 436 ₂, 436 ₃, 436 ₄, and 436 ₅ has anassociated inducting document objects 482 ₁, 482 ₂, 482 ₃, 482 ₄, and482 ₅ (collectively, inducting documents 482). The inducting documents482 include information identifying one or more of the objects 436and/or one or more orders associated with the objects 436. In someembodiments, the inducting documents 482 include machine-readableinformation and/or human-readable information. In some examples, each ofthe inducting documents 482 includes a barcode, a QR code, a RFID tag,any other form a machine-readable information, or any combinationthereof. In the depicted embodiment, each of the inducting documents 482includes a QR code. The infeed scanner 472 is configured to read the QRcodes on the inducting documents 482 if the QR codes are arrangedappropriately with respect to the infeed scanner 472. The infeed scanner472 is configured to send information to other components in thepackaging system 400, such as a labeling mechanism or a dischargescanner.

FIG. 8C depicts an outfeed portion of the packaging system 400. At thispoint, packages 434 ₁, 434 ₂, 434 ₃, and 434 ₄ (collectively, packages434) have been formed around the respective objects 436. In the depictedembodiment, the packaging system 400 includes a labeling mechanism 476configured to print or place labels 478 ₁ and 478 ₃ (collectively,labels 478) on the packages 434. The labels 478 on the packages 434 maycontain any type of human-readable and/or machine-readable information.The packaging system 400 also includes a discharge scanner 474configured to scan the packages 434 as they leave the packaging system400. In some embodiments, the discharge scanner 474 may be configured toscan any aspect of the packages, such as an optical scan of the labelson the packages 434, an optical scan of the location of one or moresides of the packages 434, a radio frequency scan of RFID tags on theinducting documents 482 inside of the packages 434, or any other type ofscan. The data obtained from the discharge scanner 474 may be used forverification that the objects 436 have been properly packaged in thepackages 434, for creation of a record of the objects 436 that are beingshipped, for passing information about the packages 434 to downstreamsystems, or for any other reason.

In the embodiment shown in FIGS. 8A to 8C, the inducting documents 482are intended to be placed on their associated objects 436 aligned withthe leading edge 452 and the left transverse edge (i.e., the left andtop sides as seen in FIGS. 8A to 8C). For example, the inductingdocument 482 ₁ is placed on the object 436 ₁ and arranged at the leadingedge 452 ₁ and the left transverse edge of the object 436 ₁. As can beseen in FIG. 8A, when the inducting document 482 ₁ is properly placed onthe object 436 ₁, the location of the QR code in the transversedirection allows the infeed scanner 472 to read the QR code as theobject 436 ₁ passes the infeed scanner 472. The information gathered bythe infeed scanner 472 can be used by the packaging system 400 toprocess the object 436 ₁ and/or the package 434 ₁. As can be seen inFIG. 8C, the labeling mechanism 476 can print and/or apply the label 478₁ on the package based on the information obtained from the infeedscanner 472. For example, shipping information for the package 434 ₁ canbe printed on the label 478 ₁ based on the scan of the inductingdocument 482 ₁ by the infeed scanner 472.

One drawback to the use of inducting documents 482 is the effect ofimproper placement of the inducting documents 482 on the objects 436.For example, the inducting document 482 ₂ is not properly placed on theobject 436 ₂ at the leading edge 452 ₂ and the left transverse edge ofthe object 436 ₂. As can be seen in FIG. 8B, the infeed scanner 472cannot scan the QR code on the inducting document 482 ₂ because theinducting document 482 ₂ is not properly placed. In this case, theinfeed scanner 472 does not “read” the inducting document 482 ₂ and doesnot signal the appropriate information to other components of thepackaging system 400. For example, the labeling mechanism 476 does notreceive the information needed to print a label for the package 434 ₂.As can be seen in FIG. 8C, there is no label on the exterior of thepackage 434 ₂ even though the package 434 ₂ has already been conveyedbeyond the labeling mechanism 476.

Another example of improper placement of an inducting document is shownwith respect to the inducting document 482 ₃ and the object 436 ₃. Asshown in FIGS. 8A and 8B, the inducting document 482 ₃ is placed on theobject 436 ₃ where it is aligned with the left transverse edge, but theinducting document 482 ₃ is not aligned with the leading edge 452 ₃. Anoperator may have placed the inducting document 482 ₃ on the objecttoward the trailing edge 454 ₃ because of the narrow width of the object436 ₃ at the leading edge 452 ₃. However, the packaging system 400 isconfigured to place the labels 478 on the packages 434 based on thelocation of the inducting document 482 ₃. In the depicted example, thepackaging system 400 is configured to place the label 478 ₃ on thepackage 434 ₁ so that the center of the label 478 ₁ is a particulardistance (e.g., 2 inches) away from the QR code on the inductingdocument 482 ₁ toward the trailing edge of the package 434 ₁. When theinducting documents 482 are properly placed with respect to the objects436 (e.g., aligned at the leading edges 452 of the objects 436), thelabels 478 are properly placed on the exterior of the packages 434. Whenthe labels 478 are not properly placed with respect to the objects 436,the labels 478 may not be placed properly. For example, the label 478 ₃is placed on the package 434 ₃ so that the center of the label 478 ₃ issame particular distance (e.g., 2 inches) away from the QR code on theinducting document 482 ₃ toward the trailing edge of the package 434 ₃.Because the inducting document 482 ₃ is not aligned with the leadingedge 452 ₃, the label 478 ₃ is located on the package 434 ₃ much closerto the trailing edge of the package 434 ₃ than the label 478 ₁ islocated on the package 434 ₁.

Another example of improper placement of an inducting document is shownwith respect to the inducting document 482 ₄ and the object 436 ₄. Asshown in FIG. 8A, the corner of the object 436 ₄ at the leading edge 452₄ and the left transverse edge is rounded. An operator may have adifficult time placing the inducting document 482 ₄ properly on such anobject. As shown in FIG. 8B, the operator may place the corner of theinducting document 482 ₄ at the rounded corner of the object 436 ₄ atthe leading edge 452 ₄ and the left transverse edge. While the depictionshown in FIG. 8C shows the package 434 ₄ without a label because thepackage 434 ₄ is upstream of the labeling mechanism 476, the labelingmechanism 476 may not properly place a label on the package 434 ₄because of the improper placement of the inducting document 482 ₄ on theobject 436 ₄.

The drawbacks of the packaging system 400 depicted in FIGS. 8A to 8C aredue to the use of the locations of the inducting documents 482 as abasis for the location of the labels 478 applied by the labelingmechanism 476. The locations of the inducting documents 482 with respectto the objects 436 are subject to errors, such as human error whenpacing the inducting documents 482 on the objects 436, errors from theinducting documents 482 moving to an improper location after properplacement on the objects 436 (e.g., a gust of air from an HVAC vent),errors from the inducting documents 482 falling off of the objects 436(e.g., due to vibration during conveyance of the objects 436 from theconveyance system 424), or any other type of error. These errors can beovercome by the use of a packaging system that places and/or printslabels on packages independently of the locations of inducting documentson objects.

Depicted in FIGS. 9A to 9C is an embodiment of a packaging system 500that prints and/or places labels on packages independently of thelocations of inducting documents on objects. In particular, thepackaging system 500 tracks the locations of the objects independentlyof the locations of inducting documents on the objects and prints and/orplaces the labels on the packages based on the locations of the objects.FIGS. 9A and 9B depict two instances of an infeed portion of a packagingsystem 500. The packaging system 500 includes a conveyance system 524that conveys objects 536 ₁, 536 ₂, 536 ₃, 536 ₄, and 536 ₅(collectively, objects 536). Each of the objects 536 includes,respectively, a leading edge 552 ₁, 552 ₂, 552 ₃, 552 ₄, and 552 ₅(collectively, leading edges 552) and a trailing edge 554 ₁, 554 ₂, 554₃, 554 ₄, and 554 ₅ (collectively, trailing edges 554). The conveyancesystem 524 is configured convey the objects 536 in a conveyancedirection 538. As the objects 536 are conveyed by the conveyance system524, the objects 536 pass by an infeed scanner 572. The infeed scanner572 is arranged to scan for identifiers on the objects 536 on theconveyance system 524.

Each of the objects 536 ₁, 536 ₂, 536 ₃, 536 ₄, and 536 ₅ has anassociated inducting document objects 582 ₁, 582 ₂, 582 ₃, 582 ₄, and582 ₅ (collectively, inducting documents 582). The inducting documents582 include information identifying one or more of the objects 536and/or one or more orders associated with the objects 536. In someembodiments, the inducting documents 582 include machine-readableinformation and/or human-readable information. In some examples, each ofthe inducting documents 582 includes a barcode, a QR code, a RFID tag,any other form a machine-readable information, or any combinationthereof. In the depicted embodiment, each of the inducting documents 582includes a QR code. The infeed scanner 572 is configured to read the QRcodes on the inducting documents 582. The infeed scanner 572 isconfigured to send information to other components in the packagingsystem 500, such as a labeling mechanism or a discharge scanner.

FIG. 8C depicts an outfeed portion of the packaging system 500. At thispoint, packages 534 ₁, 534 ₂, 534 ₃, and 534 ₄ (collectively, packages534) have been formed around the respective objects 536. In the depictedembodiment, the packaging system 500 includes a labeling mechanism 576configured to print or place labels 578 ₁, 578 ₂, and 578 ₃(collectively, labels 578) on the packages 534.

The labels 578 on the packages 534 may contain any type ofhuman-readable and/or machine-readable information. The packaging system500 also includes a discharge scanner 574 configured to scan thepackages 534 as they leave the packaging system 500. In someembodiments, the discharge scanner 574 may be configured to scan anyaspect of the packages, such as an optical scan of the labels on thepackages 534, an optical scan of the location of one or more sides ofthe packages 534, a radio frequency scan of RFID tags on the inductingdocuments 582 inside of the packages 534, or any other type of scan. Thedata obtained from the discharge scanner 574 may be used forverification that the objects 536 have been properly packaged in thepackages 534, for creation of a record of the objects 536 that are beingshipped, for passing information about the packages 534 to downstreamsystems, or for any other reason.

The packaging system 500 is also configured to track locations of theobjects 536 as they are conveyed by the conveyance system. The packagingsystem 500 may include any of the tracking systems disclosed here, suchas a position detector in the infeed portion of the conveyance system524 configured to detect an initial position of the objects 536 and anencoder in every conveyor of the conveyance system 524 to detectmovements of the objects 536 after the initial position by theconveyance system 524. In some embodiments, the packaging system 500detects the leading edges 552 and the trailing edges 554 of the objects536 at an infeed portion of the conveyance system 524. The packagingsystem 500 controls the infeed scanner 572 to detect the QR codes on theinducting documents 582 at any point between the leading edges 552 andthe trailing edges 554 of the objects 536. For example, the packagingsystem (e.g., a controller in the packaging system 500) controls theinfeed scanner to detect a QR code on the inducting document 582 ₁between the leading edge 552 ₁ and the trailing edges 554 ₁ of theobject 536 ₁, to detect a QR code on the inducting document 582 ₂between the leading edge 552 ₂ and the trailing edges 554 ₂ of theobject 536 ₂, and so forth. Significantly, the QR codes can be locatedat any longitudinal position and transverse position on the objects 536.Thus, the inducting documents 582 do not need to be as specificallypositioned on the objects 536 as the inducting documents 482 need to bepositioned on the objects 436. As long as the QR codes are located onthe objects 536, the infeed scanner 572 can scan the QR code andassociate it with the object that is beneath the QR code. Thus, theinfeed scanner 572 is able to scan both the QR code on the inductingdocument 482 ₁ and the inducting document 482 ₂ even though theinducting document 482 ₁ and 482 ₂ are not in the same position on theirrespective objects 536 ₁ and 536 ₂.

On the outfeed portion of the packaging system 500 shown in FIG. 9C, thelabeling mechanism 576 has placed labels 578 ₁, 578 ₂, and 578 ₃,(collectively, labels 578) on the respective packages 534 ₁, 534 ₂, and534 ₃. The packaging system 500 caused the labeling mechanism 576 toplace the labels 578 on the packages 534 at longitudinal locations thatare approximately centered between the leading edges 552 and thetrailing edges 554 of the object 536. The packaging system 500 alsocaused the labeling mechanism 576 to place the labels 578 irrespectiveof the locations of the inducting documents 582. The packaging system500 is able to do this because the packaging system 500 tracks thelocations of the objects 536 on the conveyance system 524 independentlyof the locations of the inducting documents 582. While the embodimentdepicted in FIG. 9C shows the labels 578 on the packages 534 atlongitudinal locations that are approximately centered between theleading edges 552 and the trailing edges 554 of the object 536, it willbe understood that the packaging system 500 could cause the labelingmechanism 576 to place and/or print a label at any location with respectto the objects 536 on the packages 534.

FIG. 10 depicts an example embodiment of a system 610 that may be usedto implement some or all of the embodiments described herein. In thedepicted embodiment, the system 610 includes computing devices 620 ₁,620 ₂, 620 ₃, and 620 ₄ (collectively computing devices 620). In thedepicted embodiment, the computing device 620 ₁ is a tablet, thecomputing device 620 ₂ is a mobile phone, the computing device 620 ₃ isa desktop computer, and the computing device 620 ₄ is a laptop computer.In other embodiments, the computing devices 620 include one or more of adesktop computer, a mobile phone, a tablet, a phablet, a notebookcomputer, a laptop computer, a distributed system, a gaming console(e.g., Xbox, Play Station, Wii), a watch, a pair of glasses, a key fob,a radio frequency identification (RFID) tag, an ear piece, a scanner, atelevision, a dongle, a camera, a wristband, a wearable item, a kiosk,an input terminal, a server, a server network, a blade, a gateway, aswitch, a processing device, a processing entity, a set-top box, arelay, a router, a network access point, a base station, any otherdevice configured to perform the functions, operations, and/or processesdescribed herein, or any combination thereof.

The computing devices 620 are communicatively coupled to each other viaone or more networks 630 and 632. Each of the networks 630 and 632 mayinclude one or more wired or wireless networks (e.g., a 3G network, theInternet, an internal network, a proprietary network, a securednetwork). The computing devices 620 are capable of communicating witheach other and/or any other computing devices via one or more wired orwireless networks. While the particular system 610 in FIG. 10 depictsthat the computing devices 620 communicatively coupled via the network630 include four computing devices, any number of computing devices maybe communicatively coupled via the network 630.

In the depicted embodiment, the computing device 620 ₃ iscommunicatively coupled with a peripheral device 640 via the network632. In the depicted embodiment, the peripheral device 640 is a scanner,such as a barcode scanner, an optical scanner, a computer vision device,and the like. In some embodiments, the network 632 is a wired network(e.g., a direct wired connection between the peripheral device 640 andthe computing device 620 ₃), a wireless network (e.g., a Bluetoothconnection or a WiFi connection), or a combination of wired and wirelessnetworks (e.g., a Bluetooth connection between the peripheral device 640and a cradle of the peripheral device 640 and a wired connection betweenthe peripheral device 640 and the computing device 620 ₃). In someembodiments, the peripheral device 640 is itself a computing device(sometimes called a “smart” device). In other embodiments, theperipheral device 640 is not a computing device (sometimes called a“dumb” device).

Depicted in FIG. 11 is a block diagram of an embodiment of a computingdevice 700. Any of the computing devices 620 and/or any other computingdevice described herein may include some or all of the components andfeatures of the computing device 700. In some embodiments, the computingdevice 700 is one or more of a desktop computer, a mobile phone, atablet, a phablet, a notebook computer, a laptop computer, a distributedsystem, a gaming console (e.g., an Xbox, a Play Station, a Wii), awatch, a pair of glasses, a key fob, a radio frequency identification(RFID) tag, an ear piece, a scanner, a television, a dongle, a camera, awristband, a wearable item, a kiosk, an input terminal, a server, aserver network, a blade, a gateway, a switch, a processing device, aprocessing entity, a set-top box, a relay, a router, a network accesspoint, a base station, any other device configured to perform thefunctions, operations, and/or processes described herein, or anycombination thereof. Such functions, operations, and/or processes mayinclude, for example, transmitting, receiving, operating on, processing,displaying, storing, determining, creating/generating, monitoring,evaluating, comparing, and/or similar terms used herein. In oneembodiment, these functions, operations, and/or processes can beperformed on data, content, information, and/or similar terms usedherein.

In the depicted embodiment, the computing device 700 includes aprocessing element 705, memory 710, a user interface 715, and acommunications interface 720. The processing element 705, memory 710, auser interface 715, and a communications interface 720 are capable ofcommunicating via a communication bus 725 by reading data from and/orwriting data to the communication bus 725. The computing device 700 mayinclude other components that are capable of communicating via thecommunication bus 725. In other embodiments, the computing device doesnot include the communication bus 725 and the components of thecomputing device 700 are capable of communicating with each other insome other way.

The processing element 705 (also referred to as one or more processors,processing circuitry, and/or similar terms used herein) is capable ofperforming operations on some external data source. For example, theprocessing element may perform operations on data in the memory 710,data receives via the user interface 715, and/or data received via thecommunications interface 720. As will be understood, the processingelement 705 may be embodied in a number of different ways. In someembodiments, the processing element 705 includes one or more complexprogrammable logic devices (CPLDs), microprocessors, multi-coreprocessors, co processing entities, application-specific instruction-setprocessors (ASIPs), microcontrollers, controllers, integrated circuits,application specific integrated circuits (ASICs), field programmablegate arrays (FPGAs), programmable logic arrays (PLAs), hardwareaccelerators, any other circuitry, or any combination thereof. The termcircuitry may refer to an entirely hardware embodiment or a combinationof hardware and computer program products. In some embodiments, theprocessing element 705 is configured for a particular use or configuredto execute instructions stored in volatile or nonvolatile media orotherwise accessible to the processing element 705. As such, whetherconfigured by hardware or computer program products, or by a combinationthereof, the processing element 705 may be capable of performing stepsor operations when configured accordingly.

The memory 710 in the computing device 700 is configured to store data,computer-executable instructions, and/or any other information. In someembodiments, the memory 710 includes volatile memory (also referred toas volatile storage, volatile media, volatile memory circuitry, and thelike), non-volatile memory (also referred to as non-volatile storage,non-volatile media, non-volatile memory circuitry, and the like), orsome combination thereof.

In some embodiments, volatile memory includes one or more of randomaccess memory (RAM), dynamic random access memory (DRAM), static randomaccess memory (SRAM), fast page mode dynamic random access memory (FPMDRAM), extended data-out dynamic random access memory (EDO DRAM),synchronous dynamic random access memory (SDRAM), double data ratesynchronous dynamic random access memory (DDR SDRAM), double data ratetype two synchronous dynamic random access memory (DDR2 SDRAM), doubledata rate type three synchronous dynamic random access memory (DDR3SDRAM), Rambus dynamic random access memory (RDRAM), Twin Transistor RAM(TTRAM), Thyristor RAM (T-RAM), Zero-capacitor (Z-RAM), Rambus in-linememory module (RIMM), dual in-line memory module (DIMM), single in-linememory module (SIMM), video random access memory (VRAM), cache memory(including various levels), flash memory, any other memory that requirespower to store information, or any combination thereof.

In some embodiments, non-volatile memory includes one or more of harddisks, floppy disks, flexible disks, solid-state storage (SSS) (e.g., asolid state drive (SSD)), solid state cards (SSC), solid state modules(SSM), enterprise flash drives, magnetic tapes, any other non-transitorymagnetic media, compact disc read only memory (CD ROM), compactdisc-rewritable (CD-RW), digital versatile disc (DVD), Blu-ray disc(BD), any other non-transitory optical media, read-only memory (ROM),programmable read-only memory (PROM), erasable programmable read-onlymemory (EPROM), electrically erasable programmable read-only memory(EEPROM), flash memory (e.g., Serial, NAND, NOR, and/or the like),multimedia memory cards (MMC), secure digital (SD) memory cards, MemorySticks, conductive-bridging random access memory (CBRAM), phase-changerandom access memory (PRAM), ferroelectric random-access memory (FeRAM),non-volatile random access memory (NVRAM), magneto-resistive randomaccess memory (MRAM), resistive random-access memory (RRAM), SiliconOxide-Nitride-Oxide-Silicon memory (SONOS), floating junction gaterandom access memory (FJG RAM), Millipede memory, racetrack memory, anyother memory that does not require power to store information, or anycombination thereof.

In some embodiments, memory 710 is capable of storing one or more ofdatabases, database instances, database management systems, data,applications, programs, program modules, scripts, source code, objectcode, byte code, compiled code, interpreted code, machine code,executable instructions, or any other information. The term database,database instance, database management system, and/or similar terms usedherein may refer to a collection of records or data that is stored in acomputer-readable storage medium using one or more database models, suchas a hierarchical database model, network model, relational model,entity relationship model, object model, document model, semantic model,graph model, or any other model.

The user interface 715 of the computing device 700 is in communicationwith one or more input or output devices that are capable of receivinginputs into and/or outputting any outputs from the computing device 700.Embodiments of input devices include a keyboard, a mouse, a touchscreendisplay, a touch sensitive pad, a motion input device, movement inputdevice, an audio input, a pointing device input, a joystick input, akeypad input, peripheral device 640, foot switch, and the like.Embodiments of output devices include an audio output device, a videooutput, a display device, a motion output device, a movement outputdevice, a printing device, and the like. In some embodiments, the userinterface 715 includes hardware that is configured to communicate withone or more input devices and/or output devices via wired and/orwireless connections.

The communications interface 720 is capable of communicating withvarious computing devices and/or networks. In some embodiments, thecommunications interface 720 is capable of communicating data, content,and/or any other information, that can be transmitted, received,operated on, processed, displayed, stored, and the like. Communicationvia the communications interface 720 may be executed using a wired datatransmission protocol, such as fiber distributed data interface (FDDI),digital subscriber line (DSL), Ethernet, asynchronous transfer mode(ATM), frame relay, data over cable service interface specification(DOCSIS), or any other wired transmission protocol. Similarly,communication via the communications interface 720 may be executed usinga wireless data transmission protocol, such as general packet radioservice (GPRS), Universal Mobile Telecommunications System (UMTS), CodeDivision Multiple Access 2000 (CDMA2000), CDMA2000 1X (1xRTT), WidebandCode Division Multiple Access (WCDMA), Global System for MobileCommunications (GSM), Enhanced Data rates for GSM Evolution (EDGE), TimeDivision-Synchronous Code Division Multiple Access (TD-SCDMA), Long TermEvolution (LTE), Evolved Universal Terrestrial Radio Access Network(E-UTRAN), Evolution-Data Optimized (EVDO), High Speed Packet Access(HSPA), High-Speed Downlink Packet Access (HSDPA), IEEE 802.11 (WiFi),WiFi Direct, 802.16 (WiMAX), ultra wideband (UWB), infrared (IR)protocols, near field communication (NFC) protocols, Wibree, Bluetoothprotocols, wireless universal serial bus (USB) protocols, or any otherwireless protocol.

As will be appreciated by those skilled in the art, one or morecomponents of the computing device 700 may be located remotely fromother components of the computing device 700 components, such as in adistributed system. Furthermore, one or more of the components may becombined and additional components performing functions described hereinmay be included in the computing device 700. Thus, the computing device700 can be adapted to accommodate a variety of needs and circumstances.The depicted and described architectures and descriptions are providedfor exemplary purposes only and are not limiting to the variousembodiments described herein.

Embodiments described herein may be implemented in various ways,including as computer program products that comprise articles ofmanufacture. A computer program product may include a non-transitorycomputer-readable storage medium storing applications, programs, programmodules, scripts, source code, program code, object code, byte code,compiled code, interpreted code, machine code, executable instructions,and/or the like (also referred to herein as executable instructions,instructions for execution, computer program products, program code,and/or similar terms used herein interchangeably). Such non-transitorycomputer-readable storage media include all computer-readable media(including volatile and non-volatile media).

As should be appreciated, various embodiments of the embodimentsdescribed herein may also be implemented as methods, apparatus, systems,computing devices, and the like. As such, embodiments described hereinmay take the form of an apparatus, system, computing device, and thelike executing instructions stored on a computer readable storage mediumto perform certain steps or operations. Thus, embodiments describedherein may be implemented entirely in hardware, entirely in a computerprogram product, or in an embodiment that comprises combination ofcomputer program products and hardware performing certain steps oroperations.

Embodiments described herein may be made with reference to blockdiagrams and flowchart illustrations. Thus, it should be understood thatblocks of a block diagram and flowchart illustrations may be implementedin the form of a computer program product, in an entirely hardwareembodiment, in a combination of hardware and computer program products,or in apparatus, systems, computing devices, and the like carrying outinstructions, operations, or steps. Such instructions, operations, orsteps may be stored on a computer readable storage medium for executionbuy a processing element in a computing device. For example, retrieval,loading, and execution of code may be performed sequentially such thatone instruction is retrieved, loaded, and executed at a time. In someexemplary embodiments, retrieval, loading, and/or execution may beperformed in parallel such that multiple instructions are retrieved,loaded, and/or executed together. Thus, such embodiments can producespecifically configured machines performing the steps or operationsspecified in the block diagrams and flowchart illustrations.Accordingly, the block diagrams and flowchart illustrations supportvarious combinations of embodiments for performing the specifiedinstructions, operations, or steps.

For purposes of this disclosure, terminology such as “upper,” “lower,”“vertical,” “horizontal,” “inwardly,” “outwardly,” “inner,” “outer,”“front,” “rear,” and the like, should be construed as descriptive andnot limiting the scope of the claimed subject matter. Further, the useof “including,” “comprising,” or “having” and variations thereof hereinis meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Unless limited otherwise, the terms“connected,” “coupled,” and “mounted” and variations thereof herein areused broadly and encompass direct and indirect connections, couplings,and mountings. Unless stated otherwise, the terms “substantially,”“approximately,” and the like are used to mean within 5% of a targetvalue.

It should be appreciated that any document, including patents and patentapplication publications, incorporated by reference herein isincorporated herein to the extent that the incorporated material doesnot conflict with existing definitions, statements, or other disclosurematerial set forth in this disclosure. If any conflict arises betweenincorporated material and the definitions, statements, or otherdisclosure material set forth in this disclosure, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference.

The principles, representative embodiments, and modes of operation ofthe present disclosure have been described in the foregoing description.However, aspects of the present disclosure which are intended to beprotected are not to be construed as limited to the particularembodiments disclosed. Further, the embodiments described herein are tobe regarded as illustrative rather than restrictive. It will beappreciated that variations and changes may be made by others, andequivalents employed, without departing from the spirit of the presentdisclosure. Accordingly, it is expressly intended that all suchvariations, changes, and equivalents fall within the spirit and scope ofthe present disclosure, as claimed.

1. A packaging system comprising: a conveyance system configured toreceive objects and to convey the objects through the packaging system,wherein spacing between the objects is non-uniform as the objects arereceived by the conveyance system; a package forming system configuredto feed a packaging material to form a tube of the packaging materialand further configured to seal the tube of the packaging material aroundthe objects to form packages of the packaging material around theobjects; and a tracking system configured to track locations of theobjects as the objects are conveyed through the packaging system on theconveyance system, wherein the tracking system is configured to tracklocations of the objects independently of any marks on the packagingmaterial.
 2. The packaging system of claim 1, wherein the trackingsystem comprises: an infeed scanner configured to detect an infeedlocation of each of the objects as the objects are fed through an infeedportion of the conveyance system.
 3. The packaging system of claim 2,wherein the infeed scanner is configured to detect the infeed locationof each of the objects by detecting a leading edge and a trailing edgeof each of the objects as the objects are fed through the infeed portionof the conveyance system.
 4. The packaging system of claim 3, whereinthe tracking system is configured to calculate a longitudinal length ofeach of the objects based on the leading edge and the trailing edge ofeach of the objects.
 5. The packaging system of claim 4, wherein thepackage forming system is configured to seal the tube of the packagingmaterial around one of the objects at locations based on thelongitudinal length of the one of the objects.
 6. The packaging systemof claim 4, wherein: the infeed scanner is further configured togenerate a height indication for each of the objects as the objects arefed through the infeed portion of the conveyance system; the heightindication for an object includes at least one of an indication whetherany portion of the object exceeds a predetermined height, an indicationof a height of the leading edge of the object and a height of thetrailing edge of the object, or a height profile of the object from atransverse side of the object; and the package forming system isconfigured to seal the tube of the packaging material around one of theobjects at locations based on a combination of the longitudinal lengthof the one of the objects and the height indication of the one of theobjects.
 7. The packaging system of claim 2, wherein the tracking systemfurther comprises: at least one conveyor sensor configured to detectmovements of the conveyance system; wherein the tracking system isconfigured to track locations of the objects as the objects pass throughthe packaging system on the conveyance system based on a combination ofthe infeed location of each of the objects and the movements of theconveyance system detected by the at least one conveyor sensor.
 8. Thepackaging system of claim 7, wherein the at least one conveyor sensorincludes a plurality of encoders configured detect movements of each ofa plurality of conveyor belts in the conveyance system. 9.-11.(canceled)
 12. A method comprising: receiving, by a conveyance system ofa packaging system, objects that are non-uniformly spaced as the objectsare received by the conveyance system; conveying, by the conveyancesystem, the objects through the packaging system; feeding, by a packageforming system of the packaging system, a packaging material to form atube of the packaging material; forming, by the package forming system,seals in the tube of the packaging material around the objects to formpackages of the packaging material around the objects; and tracking, bya tracking system in the packaging system, locations of the objectsindependently of any marks on the packaging material as the objects areconveyed through the packaging system.
 13. The method of claim 12,further comprising: detecting, by an infeed scanner of the trackingsystem, an infeed location of each of the objects as the objects are fedthrough an infeed portion of the conveyance system.
 14. The method ofclaim 13, wherein detecting the infeed location of each of the objectsincludes detecting a leading edge and a trailing edge of each of theobjects as the objects are fed through the infeed portion of theconveyance system.
 15. The method of claim 14, further comprisingcalculating, by the tracking system, a longitudinal length of each ofthe objects based on the leading edge and the trailing edge of each ofthe objects.
 16. The method of claim 15, wherein the package formingsystem is configured to seal the tube of the packaging material aroundone of the objects at locations based on the longitudinal length of theone of the objects.
 17. The method of claim 14, further comprising:generating, by the infeed scanner, a height indication for each of theobjects as the objects are fed through the infeed portion of theconveyance system; wherein the height indication for an object includesat least one of an indication whether any portion of the object exceedsa predetermined height, an indication of a height of the leading edge ofthe object and a height of the trailing edge of the object, or a heightprofile of the object from a transverse side of the object; and whereinthe package forming system is configured to seal the tube of thepackaging material around one of the objects at locations based on acombination of a longitudinal length of the one of the objects and theheight indication of the one of the objects.
 18. The method of claim 13,further comprising: detecting, by at least one conveyor sensor of thetracking system, movements of the conveyance system; wherein trackingthe locations of the objects as the objects are conveyed through thepackaging system on the conveyance system is based on a combination ofthe infeed location of each of the objects and the movements of theconveyance system detected by the at least one conveyor sensor.
 19. Themethod of claim 18, wherein the at least one conveyor sensor includes aplurality of encoders configured detect movements of each of a pluralityof conveyor belts in the conveyance system. 20.-38. (canceled)
 39. Apackaging system comprising: a conveyance system configured to receiveobjects, wherein spacing between the objects is non-uniform as theobjects are received by the conveyance system; a package forming systemconfigured to feed a packaging material to form a tube of the packagingmaterial and to form transverse seals in the tube of the packagingmaterial; and a tracking system configured to track locations of theobjects as the objects are conveyed through the packaging system on theconveyance system; wherein the conveyance system is configured to feedthe objects into the tube of the packaging material; wherein at leastone of the objects is located between two of the transverse seals toform a package of the packaging material around the at least one of theobjects; wherein the tracking system is configured to track thelocations of the objects at least by tracking the location of the atleast one of the objects while the at least one of the objects is insideof the tube of the packaging material and inside of the package; whereinthe packaging system is configured to pass the package to a downstreampackage handling system and to communicate, to the downstream packagehandling system, the location of the at least one object.
 40. Thepackaging system of claim 39, wherein: the packaging system isconfigured to determine that the package is flawed; and the packagingsystem is further configured to communicate, to the downstream packagehandling system, an indication that the package is flawed.
 41. Thepackaging system of claim 40, wherein the downstream package handlingsystem is configured to sort the package from other packages that arenot flawed based at least on the location of the package and theindication that the package is flawed received from the packagingsystem.
 42. The packaging system of claim 40, wherein the packagingsystem is configured to determine that the package is flawed is based onat least one of a determination that the package is lacking one of theobjects, a determination that the package includes an extra one of theobjects, a faulty reading of a label on the package, a lack of a labelon the package, an improper dimension of the package, a transverse sealon the package that crosses a graphic region, a user input indicatingthat the package is flawed, or any combination thereof.
 43. Thepackaging system of claim 39, wherein the packaging system iscommunicatively coupled to the downstream package handling system viaone or more of a serial connection, a communication bus, a wirednetwork, or a wireless network. 44.-48. (canceled)